Cutting forces modeling considering the effect of tool thermal property—application to CBN hard turning

Huang, Yong; Liang, Steven Y.

doi:10.1016/s0890-6955(02)00185-2

Cited by 131 publications

(67 citation statements)

References 10 publications

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“…In reality, however, this is not true. When highly dynamic force components in hard machining are properly measured by experience researchers, the cutting speed has very strong influence on these components in hard machining with PCBN, ceramic, and cermet tool materials [16][17][18], which is the essence of hard machining. For example, Remadna and Rigal [18] pointed out that "The specific cutting force K sc decreases regularly when the cutting speed increases from 50 to 350 m/min and regardless of the wear VB", as shown in Figure 1.5.…”

Section: Short Critical Analysis Of the Research On Hard Machiningmentioning

confidence: 99%

Machining of Hard Materials – Definitions and Industrial Applications

Astakhov

2011

Machining of Hard Materials

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Section: Short Critical Analysis Of the Research On Hard Machiningmentioning

confidence: 99%

Machining of Hard Materials – Definitions and Industrial Applications

Astakhov

2011

Machining of Hard Materials

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“…1. With the information of material properties of the workpiece and the CBN tool in turning hardened steel, the process information, such as cutting forces, shear angle, shear flow stress, and the interface temperature distribution can be estimated by applying modified predictive machining theory [19] for a fresh tool. With known and/or calibrated wear coefficients, the tool crater wear rate can be estimated.…”

Section: The General Approach Of Modelling Crater Wear Progressionmentioning

confidence: 99%

Modelling of CBN tool crater wear in finish hard turning

Huang

Liang

2004

Int J Adv Manuf Technol

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The wear of cubic boron nitride (CBN) cutters, commonly used now in the finish turning of hardened parts, is an important issue that needs to be addressed for hard turning to be a viable technology due to the high costs of CBN cutters and the down-time for tool change. Chipping and tool breakage, which lead to early tool failure, are both prone to take place under the effect of crater wear. The objective of this study is to develop a methodology to model the CBN tool crater wear rate to both guide the design of CBN tool geometry and optimise cutting parameters in finish hard turning. First, the wear volume losses due to the main wear mechanisms (abrasion, adhesion, and diffusion) are modelled as functions of cutting temperature, stress, and other process attributes respectively. Then, the crater wear rate is predicted in terms of tool/work material properties and cutting configuration. Finally, the proposed model is experimentally validated in finish turning of hardened 52100 bearing steel using a low CBN content insert. The comparison between the prediction and the measurement shows reasonable agreement and the results suggest that adhesion is the main wear mechanism over the investigated range of cutting conditions. D 0 Diffusion coefficient related to the frequency of atomic oscillations (m 2 /s) D Coefficient of diffusion (m 2 /s) f Feed (m) h Contact length (m) K Dimensionless constant K abrasion Process related dimensionless abrasive wear coefficient K adhesion Process related adhesive wear coefficient (m 3 /N) K diff Process related diffusive wear coefficient (ms − 1 2 ) K Q Constant related with activation energy for diffusion (K) l 1 Length within where normal stress in uniform (m) l f Sliding length (m) l s Sticking length (m) n Dimensionless constant P a Hardness of the abrasive particle (N/mm 2 ) P t Tool hardness (N/mm 2 ) Q Activation energy for diffusion (Cal/mole) r Tool nose radius (m) R Gas constant (Cal/mole · K) t max Maximum undeformed chip thickness along the tool cutting edge (m) T(x) Temperature distribution along the interface • C V chip (x) Chip velocity along the tool rake face (m/s) V wear-abrasion Tool volume loss due to abrasion within time interval (m 3 ) V wear-adhesion Tool volume loss due to adhesion within time interval (m 3 ) V wear-diff Tool volume loss due to diffusion within time interval (m 3 ) w Width of cut (m) ∆K T (x) Crater wear depth change along the contact length (µm) ∆t Time interval (s) ∆V wear Tool material removed within time interval ∆t(m 3 ) ∆x Length of an infinitesimal segment AB along the interface (m) σ(x) Normal stress along the tool-chip interface (N/m 2 ) 633

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“…The temperature increase due to the heat source in the SSZ was solved using a modified Jaeger's moving band heat source model in the chip, and a stationary rectangular heat source model in the tool [29]. Liang et al further developed this model to predict temperature distribution with considerations of the tool thermal properties and the tool wear effects [30,31]. Liang et al also developed a cutting temperature model with an assumption of non-uniform heat intensity and partition ratio, and reported improved accuracy upon validation [32].…”

Section: Introductionmentioning

confidence: 99%

Prediction of Temperature Distribution in Orthogonal Machining Based on the Mechanics of the Cutting Process Using a Constitutive Model

Ning

Liang

2018

JMMP

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This paper presents an original method of predicting temperature distribution in orthogonal machining based on a constitutive model of various materials and the mechanics of their cutting process. Currently, temperature distribution is commonly investigated using arduous experiments, computationally inefficient numerical analyses, and complex analytical models. In the method proposed herein, the average temperatures at the primary shear zone (PSZ) and the secondary shear zone (SSZ) were determined for various materials, based on a constitutive model and a chip-formation model using measurements of cutting force and chip thickness. The temperatures were determined when differences between predicted shear stresses using the Johnson-Cook constitutive model (J-C model) and those using a chip-formation model were minimal. J-C model constants from split Hopkinson pressure bar (SHPB) tests were adopted from the literature. Cutting conditions, experimental cutting force, and chip thickness were used to predict the shear stresses. The temperature predictions were compared to documented results in the literature for AISI 1045 steel and Al 6082-T6 aluminum in multiple tests in an effort to validate this methodology. Good agreement was observed for the tests with each material. Thanks to the reliable and easily measurable cutting forces and chip thicknesses, and the simple forms of the employed models, the presented methodology has less experimental complexity, less mathematical complexity, and high computational efficiency.

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Cutting forces modeling considering the effect of tool thermal property—application to CBN hard turning

Cited by 131 publications

References 10 publications

Machining of Hard Materials – Definitions and Industrial Applications

Machining of Hard Materials – Definitions and Industrial Applications

Modelling of CBN tool crater wear in finish hard turning

Prediction of Temperature Distribution in Orthogonal Machining Based on the Mechanics of the Cutting Process Using a Constitutive Model

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