Investigation of the effect of rake angle on main cutting force

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

doi:10.1016/j.ijmachtools.2004.01.015

Cited by 72 publications

(28 citation statements)

References 6 publications

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“…Main cutting force increases with increased negative rake angle values and decreases with increased positive rake angle values. Main cutting force for all cutting speeds is high for negative rake angles [66].…”

Section: Modeling Techniques With Tool Geometrymentioning

confidence: 97%

Untitled

2011

JESTR

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The effect of cutting tool geometry has long been an issue in understanding mechanics of turning. Tool geometry has significant influence on chip formation, heat generation, tool wear, surface finish and surface integrity during turning. This article presents a survey on variation in tool geometry i.e. tool nose radius, rake angle, groove on the rake face, variable edge geometry, wiper geometry and curvilinear edge tools and their effect on tool wear, surface roughness and surface integrity of the machined surface. Further modeling and simulation approaches on tool geometry including one approach developed in a recent study, on variable micro-geometry tools, is discussed in brief.Keywords: Curvilinear edge, rake angle, grooved tools, nose radius, variable geometry. Stringent control on the quality of machined surface and sub-surface during turning is most important consideration a part from considering the tool life. In order to attain sufficiently high production rates at minimum cost, optimization of cutting tool geometry is necessary [1], [2]. The design of cutting edge geometry and its influence on machining performance have been a research topic in metal cutting for a long time. Edge preparation has a critical effect on the tool life. A tool with poor edge preparation may chip and fail quickly [3]. Users expect to have more and more productivity in their machining processes (high removal rate of work-material) and low wear of their cutting tools (long tool life). These demands require major improvements in the design of cutting tools: new substrates, new coatings, cutting tool geometry and materials etc. According to tool manufacturers, the manufacturing procedures of their cutting tools, especially the micro-geometry preparation (cutting edge etc.), have a major influence on their performance and on their reliability [4]. Edge preparation must be carefully selected for a given application because it affects the surface integrity of the machined workpiece (white layer, residual stresses etc.) [5]. Heat generated during hard turning is also affected by edge preparation due to change in work material flow around the cutting edge. For example, a chamfered face provides excessive negative angle to the cutting action and results in high heat generation. PCBN tools rapidly wear out during hard turning at high cutting speeds mainly due to attained temperatures [6].It is important to consider the tool-edge effect in order to better understand the chip formation mechanism and accurately predict machining performances, such as cutting forces, cutting temperatures, tool wear, surface finish and the machined surface integrity. The methods commonly employed include experimental, analytical, and numerical methods [7]. The tool geometry effects on turning performance parameters are mentioned in Figure1.It is demonstrated that the cutting tool edge geometry significantly influences many fundamental aspects such as cutting forces, chip formation, cutting temperature, tool wear, tool-life and characteristics like sur...

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Section: Modeling Techniques With Tool Geometrymentioning

confidence: 97%

Untitled

2011

JESTR

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“…En düşük çekme kalıntı gerilmeleri (çevresel ve eksenel); kesme hızı 200 m/dak, ilerleme miktarı 0,1 mm/dev ve kesme derinliği 1,25 mm olduğunda, en yüksek çekme kalıntı gerilmeleri (çevresel ve eksenel) ise; kesme hızı 125 m/dak, ilerleme miktarı 0,3 mm/dev ve kesme derinliği 2,5 mm olduğunda elde edilmiştir. [37][38][39][40], takım/talaş temas uzunluğu ve sürtünme kuvveti artacağından [40,43], iş parçasına iletilen ısı miktarı da artacaktır. Ayrıca, MM formlu kesici takımla elde edilmiş kesme kuvvetleri MF formlu kesici takımla elde edilmiş olan kesme kuvvetlerinden daha yüksek çıkmıştır (Şekil 2).…”

Section: çEkme Kalıntı Gerilmeler (Tensile Residual Stresses)unclassified

AISI 316L çeliğinin tornalanmasında kesici takım formlarının yüzey bütünlüğü üzerine etkisi

Gürbüz

Kafkas

Şeker

2019

Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi

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Highlights:Graphical/Tabular Abstract  It was found that cutting parameters have a significant effect on surface integrity.  Surface integrity results obtained with cutting tools with MF turned out to be better than those obtained with cutting tools with MM.  As the rake angle increased, the surface integrity improved as well. Purpose:The aim of this conducted study, depending on the different cutting tool forms and the change in cutting parameters, can be summarized as measurement of the surface roughness on machined workpieces and the cutting forces formed during the cutting experiments, and determination of the residual stresses having occurred after machining, and establishing metallurgical structure of the surface layers (determination of microstructural changes and measurement of microhardness) and exhibiting the relation of all of them with each other, and improvement of surface integrity. Theory and Methods:TC-35 JOHNFORD brand CNC lathe was used in the experiments. The cutting forces were measured with a dynamometer of KISTLER 9275B type. The Mahr Perthometer M1 surface roughness meter was used to measure the surface roughness of the workpieces. The residual stresses were determined by X-ray diffraction technique using sin 2 ψ method. SHIMADZU HMV2 microhardness device was used to measure the hardness of the specimens occurring during chip removal processes. Microstructural characterization studies were performed with Jeol JSM 6060LV model Scanning Electron Microscope (SEM). Results:The findings obtained from this experimental study were evaluated and summarized as follows.In all cutting conditions, surface integrity was observed to get worsened when depth of cutting and feed value were increased, while it improved with the increase in cutting speed. When the cutting tool forms were compared, the best surface integrity results were obtained with MF-shaped cutting tools; however, the worst surface integrity results were obtained with MM-shaped cutting tools. As rake angle increased, surface integrity also improved. While the best surface integrity was obtained when the cutting speed was 200 m/min, the feed rate was 0.1 mm/rev and the depth of cut was 1.25 mm, the worst surface integrity was obtained when the cutting speed was 125 m/min, the feed rate was 0,3 mm/rev and the depth of cut was 2,5 mm. Conclusion:As a result of literature review, no work, where the effects of cutting tool forms and cutting parameters on surface integrity have been undertaken as a whole in machining of AISI 316L austenitic stainless steel, has been encountered. By doing so, it is a basic objective to determine the optimum shape of the cutting tool form affecting chip formation during the metal removal process, thereby minimize the variations in cutting forces, and ensure a good surface quality, and provide that the residual stresses on the machined surfaces are at minimum level. In this context, it will be another goal to keep the chip formation at optimum level, and reduce the negative effect of residual stresses on chip re...

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“…As the feed rate increases to 0.35mm/rev, with all respective speeds tool life is decreases due to rapid movement which causes the chattering and rubbing action it generate high pressure that are exerted on the chip-tool interface and tool-workpiece generate wear, also high temperature at primary and secondary zone, it loses strength of the cutting point and which results less tool life. [7,8,14].It is evident that the longer tool life in case of multilayer coated tool as compare to single layer coated tool, due its toughness and lower cutting forces, thus enabling them to perform better at higher cutting conditions [6,7,8].Also it can be as tools with CVD -Ti ( C, N)/Al2O3/TiN coated carbide tools indicate higher resistance to abrasive wear and they can be recommended to roughing operation [9] . The wear initially starts with faster rate caused by micro chipping at the sharp cutting edge (edge failure), also intensive pressure and dynamic loading on cutting edges which leads to tool fracture (broken) shown in Fig 5d.…”

Section: Effect Of Feed Rates On Tool Lifementioning

confidence: 99%