Experimental study on the evolution of chip morphology, chip formation, and surface topography with cutting parameters, and their relationships in dry milling of cast aluminum alloy with PCD inserter

Chen, Xuelin; Tang, Jinyuan; Ding, Han; Liu, Anmin

doi:10.1007/s12206-021-0328-3

Cited by 9 publications

(5 citation statements)

References 33 publications

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“…The relative larger difference between the predicted and measured cutting forces at low cutting speed is caused by the work-hardening and acoustic softening effects, which are ignored in the proposed model. The difference reduces significantly because the work-hardening effect decreases rapidly with the increased cutting speed [ 2 ]. The trend of cutting forces (Fx, Fz) in convectional cutting, which increases first and then decreases with the increase of cutting speed, also indicates this.…”

Section: Resultsmentioning

confidence: 99%

“…The superior properties of high-strength metallic materials such as titanium alloys, nickel-based super-alloys, and high strength steel, etc., as well as their unique performance in a wide range of applications, including aerospace, aviation, automobile, and many other industries, have driven tremendous scientific interest [ 1 ]. However, poor machinability and high machining cost have hindered these materials’ usage due to their properties of high strength, low thermal conductivity, and unique chip formation [ 2 ]. Machining with traditional methods would inevitably result in large cutting force [ 3 ], high cutting temperature, rapid tool wear, and poor surface integrity [ 4 ].…”

Section: Introductionmentioning

confidence: 99%

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An Analytical and Experimental Study on Cutting Characteristics and Transient Cutting Force Modeling in Feed Directional Ultrasonic Vibration-Assisted Cutting of High Strength Alloys

Chen

Tang²,

Shao³

et al. 2022

Materials

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Ultrasonic vibration-assisted cutting (UVC) is progressively being used in machining as it can significantly promote the fabrication process. However, the ultrasonic vibration affecting the cutting process is still controversial. The full-transient cutting process is proposed in this study to analyze the affecting mechanism induced by ultrasonic vibration in the cutting process. This novel model is the first developed based on the fact that ultrasonic vibration would change mechanical behaviors and the cutting process. For example, the reduction of shear flowing stress in the primary shear zone and alteration of the shear angle in the UVC process. Then, considering those coupled effects, a novel model is proposed to determine the average and transient cutting forces. Here, insight and understanding into the physical phenomenon in UVC are provided. The effectiveness of the proposed model is verified by comparison with experimental results and analytical models available in the literature, with cutting parameters varying from macro to micro-scale. The results show that the ultrasonic vibration affects the cutting process in a complicated way, which is determined by transient characteristics, acoustic softening, thermal softening, plowing, and friction. Those effects on cutting performances in the UVC process under various cutting scenarios are investigated and discussed systematically. The average deviation of cutting forces between experiments and values predicted by the proposed model for Ti6Al4V, AISI 1045, and Al6063 is about 7%, 10.2%, and 11%, respectively. The deviation decreases with the increase of cutting speed in the machining of Ti6Al4V, which is different from the machining of other materials. This is contributed by the varied effect of ultrasonic vibration on the cutting process.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

An Analytical and Experimental Study on Cutting Characteristics and Transient Cutting Force Modeling in Feed Directional Ultrasonic Vibration-Assisted Cutting of High Strength Alloys

Chen

Tang²,

Shao³

et al. 2022

Materials

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“…As a kind of human invention creation tools, CNC cutting tools from birth to now, less than one hundred years of history, but the depth of its application, is beyond any kind of cutting tool, has dozens of its classification alone, such as coming up from the application of nc tool cutting process classification, can be divided into cutting and drilling, etc., each kind of nc tool has the characteristics of different On this basis, it can adapt to the production of parts of different products [4]. For all CNC tools, the parameters set during cutting will have a great impact on the actual production efficiency and quality.…”

Section: Cnc Toolmentioning

confidence: 99%

Influence of Numerical Control Cutting Parameters on Performance of Numerical Control Tool

Sha¹

2021

J. Phys.: Conf. Ser.

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As China has stepped into a new era of development, the popularity of computer applications is becoming more and more profound. Especially in the machinery manufacturing industry, the current market has put forward a higher requirement for the accuracy and toughness of machinery manufacturing, and the traditional artificial manufacturing has not been adapted to the development of the industry. Through numerical control technology, numerical control tool manufacturing process can become very standardized, its accuracy and toughness is also guaranteed. This paper will from the numerical control this point of view, to explore the influence of numerical control cutting parameters on the numerical control tool.

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“…In recent years, researchers around the world have shown significant interest in the machining of aluminium alloys [4]. Chen et al [5] demonstrated that the surface characteristics of cast aluminum alloy are intricately linked to chip shape and the way chips are formed. As a result, they proposed an optimisation strategy aimed at improving manufacturing efficiency and achieving superior surface quality.…”

Section: Introductionmentioning

confidence: 99%

Simulation and Experimental Study of the Termo-Mechanical Effect of the Milling Process of 7075 Aluminium Alloy

Habrat,

Lisowicz,

Tymczyszyn

et al. 2024

Adv. Sci. Technol. Res. J.

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This study combined simulation and experimental tests to analyse the cutting performance of three solid carbide end mills with distinct geometries during the milling of the 7075 aluminium alloy. For the tests, three uncoated end mills were employed, which differed in rake angle, clearance angle, and helical pitch. Simulation tests revealed temperature distributions and the resultant cutting forces. The machining with a milling cutter with a higher blade angle was shown to cause an increase in the temperature in the cutting zone. However, during machining with a sharper blade of cutting tool, a decrease of cutting forces was not observed. The simulated temperature distribution on the cutting edge of the cutting tool may justify significant differences in the dynamics of changes in the cutting force components during the period of operational wear.

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Experimental study on the evolution of chip morphology, chip formation, and surface topography with cutting parameters, and their relationships in dry milling of cast aluminum alloy with PCD inserter

Cited by 9 publications

References 33 publications

An Analytical and Experimental Study on Cutting Characteristics and Transient Cutting Force Modeling in Feed Directional Ultrasonic Vibration-Assisted Cutting of High Strength Alloys

An Analytical and Experimental Study on Cutting Characteristics and Transient Cutting Force Modeling in Feed Directional Ultrasonic Vibration-Assisted Cutting of High Strength Alloys

Influence of Numerical Control Cutting Parameters on Performance of Numerical Control Tool

Simulation and Experimental Study of the Termo-Mechanical Effect of the Milling Process of 7075 Aluminium Alloy

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