Experimental investigation of the effect of cutting tool rake angle on main cutting force

Günay, Mustafa; Korkut, İ̇hsan; Aslan, Ersan; Şeker, Ulvi

doi:10.1016/j.jmatprotec.2004.07.092

Cited by 70 publications

(43 citation statements)

References 9 publications

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“…Transition from the rake angle of -15 deg to +15 deg caused the decrease of the cutting force from 688 N to 365 N. In other words, the increase of the rake angle from 0 deg to +15 deg had reduced the cutting force from 610 N to 365 N, on the other hand, increasing the rake angle had increased the cutting from 610 N to 688 N. This phenomenon is agreeable with the experiment done by Gunay, et al [10]. According to him, the main cutting force was reduced by increasing the rake angle in positive direction and was increased by increasing rake angle in negative direction.…”

Section: Figuresupporting

confidence: 90%

Effect of Rake Angle on Stress, Strain and Temperature on the Edge of Carbide Cutting Tool in Orthogonal Cutting Using FEM Simulation

Yanda¹,

Ghani²,

Haron³

2010

itbj.eng.sci.

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Abstract. Demand for higher productivity and good quality for machining parts has encourage many researchers to study the effects of machining parameters using FEM simulation using either two or three dimensions version. These are due to advantages such as software package and computational times are required. Experimental work is very costly, time consuming and labor intensive. The present work aims to simulate a three-dimensional orthogonal cutting operations using FEM software (deform-3D) to study the effects of rake angle on the cutting force, effective stress, strain and temperature on the edge of carbide cutting tool. There were seven runs of simulations. All simulations were performed for various rake angles of -15 deg, -10 deg, -5 deg, 0 deg, +5 deg, +10 deg, and +15 deg. The cutting speed, feed rate and depth of cut (DOC) were kept constant at 100 m/min, 0.35 mm/rev and 0.3 mm respectively. The work piece used was ductile cast iron FCD500 grade and the cutting tool was DNMA432 series (tungsten, uncoated carbide tool, SCEA = 0; and radius angle 55 deg). The analysis of results show that, the increase in the rake angle from negative to positive angle, causing the decrease in cutting force, effective stress and total Von Misses strain. The minimum of the cutting force, effective stress and total Von Misses strain were obtained at rake angle of +15 deg. Increasing the rake caused higher temperature generated on the edge of carbide cutting tool and resulted in bigger contact area between the clearance face and the workpiece, consequently caused more friction and wear. The biggest deformation was occurred in the primary deformation zone, followed by the secondary deformation zone. The highest stress was also occurred in the primary deformation zone. But the highest temperature on the chip usually occurs in secondary deformation zone, especially in the sliding region, because the heat that was generated in the sticking region increased as the workpiece was adhered by the tool and later it was sheared in high frictional force.

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Section: Figuresupporting

confidence: 90%

Effect of Rake Angle on Stress, Strain and Temperature on the Edge of Carbide Cutting Tool in Orthogonal Cutting Using FEM Simulation

Yanda¹,

Ghani²,

Haron³

2010

itbj.eng.sci.

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“…For example, increasing the rake angle from +15 deg to +20 deg, will reduce the cutting force from 346 N to 239 N, stress from 4320 MPa to 3565 MPa, strain from 6.11 to 5.03 mm/mm and temperature from 321 o C to 299 o C. This can be accepted that the reducing in cutting force, stress, strain and temperature were resulted from reduction of tool/chip contact area, so the cutting force and friction are expected to be decreased. This is agreeable with theory and experiment done by Gunay et al [10].…”

Section: Simulation Results and Discussionsupporting

confidence: 94%

Application of FEM in Investigating Machining Performance

Yanda

Ghani²,

Haron³

2011

AMR

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Abstract.The two biggest problems that often experienced in machining cast iron are poor machinability and high hardness. Up to now, many researchers have investigated machining performance and how to find optimum condition in machining ductile cast iron. This study aims to investigate the machining performance of ductile cast iron and carbide cutting tool using FEM. Performances were evaluated by changing the cutting tool geometries on the machining responses of cutting force, stress, strain, and generated temperature on the workpiece. Deform-3D commercial finite element software was used in this study. Ductile cast iron FCD 500 grade was used as the work piece material and carbide insert DNMA432 type with WC (Tungsten) was used for the cutting tool. The effects of rake and clearance angles were investigated by designing various tool geometries. Various combination of carbide insert geometries were designed using Solid Work to produce +15, +20 and +30 deg for rake angle and 5, 7, 8 and 9 deg for clearance angle. Machining condition for the simulations were remained constant at cutting speed of 200 m/min, feed rate of 0.35 mm/rev, and depth of cut of 0.3 mm. The results of effective-stress, strain and generated temperature on both chip and material surface were analysed. The results show that by increasing the rake angle (α), it will improves the machining performance by reducing the cutting force, stress, strain and generated temperature on surface of workpiece. But, by increasing the clearance angle (γ), it will not affect much to the cutting force, stress, strain and generated temperature on chip.

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“…The processing parameters have to be optimal in order to minimize the cost and use of production materials while not decreasing the product quality. Regarding the product quality and particularly the cost, the hardening which is seen during the planing process and the cutting power were seen to both have a significant effect [6].…”

Section: Introductionmentioning

confidence: 97%

“…Gunay et al [8] stated that the cutting power used during sawdust holding directly affects cutting performance and cost of the parts. Also, it was stated that even when the cutting parts of the machinery used for metal and metalderived materials processing are sharp enough, they were found to harden against the stretches that occur during sawdust holding.…”

Section: Introductionmentioning

confidence: 99%

Determination of machinery and knife strains in the planing of wood-based panels

Gürleyen¹,

Budakçı

2015

J Wood Sci

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In this study, strains that are caused by woodbased panels on horizontal milling machines and other cutting devices were examined. In order to fulfill this aim, samples of wood-based panels such as particleboard, medium density fiberboard (MDF), blockboard, okoume (Aucoumea klaineana) plywood, poplar (Populus 9 euramericana) plywood, and oriented strand board (OSB) were examined. The strains that milling machines and planer head with reversible knives suffered were measured by an amperemeter using an experimental mechanism with six different wood-based panels, three different engine revolution speeds (rev/min), and three drive forward speeds (m/min). Using the experimental data and the data derived from wood-based panels, engine revolution speed, and drive forward speed, several regression equations were developed in order to anticipate probable strains for each of the wood-based panels. As a consequence, the utmost strains observed on machinery during planing were caused by okoume plywood, followed by MDF, OSB, particleboard, blockboard, and poplar plywood in decreasing order of intensity. It was also observed that the spent current values (A) increased during planing in which engine revolution speed and drive forward speed are always kept high. It was also clearly seen that the wood-based panels were more resistant to the machinery and the knives when they were operated at higher speeds. The results of experiments correlated well with the predicted values produced by the anticipation regression models (R 2 = 0.898-0.965).

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Experimental investigation of the effect of cutting tool rake angle on main cutting force

Cited by 70 publications

References 9 publications

Effect of Rake Angle on Stress, Strain and Temperature on the Edge of Carbide Cutting Tool in Orthogonal Cutting Using FEM Simulation

Effect of Rake Angle on Stress, Strain and Temperature on the Edge of Carbide Cutting Tool in Orthogonal Cutting Using FEM Simulation

Application of FEM in Investigating Machining Performance

Determination of machinery and knife strains in the planing of wood-based panels

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