Investigation on cutting edge preparation and FEM assisted optimization of the cutting edge micro shape for machining of nickel-base alloy

Tiffe, M.; Aßmuth, Robert; Saelzer, Jannis; Biermann, Dirk

doi:10.1007/s11740-019-00900-8

Cited by 15 publications

(7 citation statements)

References 17 publications

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“…Tool wear rate can be calculated by the wear model proposed by Usui et al [ 1 ], which is dependent on the contact stress and cutting temperature. Tiffe et al [ 2 ] found optimal cutter edge profiles to reduce tool temperature using the finite element method (FEM) technique. The edge profiles had complex shapes and the results of their work were beneficial for analyzing the thermal gradient and how it affects tool life.…”

Section: Introductionmentioning

confidence: 99%

Optimal fabrication of a thin-film thermocouple (TFTC) using Alumel/chromel junctions

Kim,

Kwak,

Shin

et al. 2024

Heliyon

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Section: Introductionmentioning

confidence: 99%

Optimal fabrication of a thin-film thermocouple (TFTC) using Alumel/chromel junctions

Kim,

Kwak,

Shin

et al. 2024

Heliyon

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“…It improves tool wear resistance, and tool life, as well as having effects on chip formation, and mechanical and thermal stresses. Biermann et al [4] proposed a finite element analysis-based methodology of the optimization of prepared cutting-edge micro forms that reduce tool wear during the machining of Inconel 718. They found that an asymmetrical micro shape is the optimal cutting-edge profile, by investigating cutting-edge parameters S α , S β and S γ .…”

Section: Introductionmentioning

confidence: 99%

A Numerical Model for Predicting the Effect of Tool Nose Radius on Machining Process Performance during Orthogonal Cutting of AISI 1045 Steel

et al. 2022

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This paper presents the development of a numerical model for predicting and studying the effects of tool nose geometries and its interactions with cutting parameters during orthogonal cutting of AISI 1045 steel. The process performance characteristics studied were cutting temperature, effective stress, cutting forces and tool wear. The cutting simulations were done using the commercial DEFORM-2D R V 11.3 software, based on the finite element method (FEM). The cutting tool used had a round nose with various nose radii (0.01–0.9 mm), while the machining parameters tested were the feed rate (0.1–0.3 mm/rev), the cutting speed (100-500 m/min) and the rake angle (–5° to +10°). The interactions between the tool nose radius and the cutting parameters (speed, feed) were found to affect mostly the cutting stress and, slightly, the tool wear rate. These interactions did not much influence the cutting temperature, that was found to be high when the tool nose radius and/or the cutting speed were high. The maximum temperature was found to occur at the middle of the tool-chip contact length and at the interaction of nose radius and flank face of the tool. Except for some fluctuations, there was no significant difference in tool wear rate between small and large nose radius scales.

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“…In order to take into account the progressive wear-related geometry change and the associated change in tool load in the simulation, the approach proposed by Yen et al [17] was applied. Tiffe et al [18] utilized the Usui wear rate, which was calculated based on a two-dimensional simulation approach for the machining of nickel-based alloys, as an optimization criterion for the design of cutting edge geometry.…”

Section: Introductionmentioning

confidence: 99%

FE-Simulation Based Design of Wear-Optimized Cutting Edge Roundings

Bergmann

Denkena

Beblein³

et al. 2021

JMMP

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The performance of cutting tools can be significantly enhanced by matching the cutting edge rounding to the process and material properties. However, the conventional cutting edge rounding design is characterized by a significant number of experimental machining studies, which involve considerable cost, time, and resources. In this study, a novel approach to cutting edge rounding design using FEM-based chip formation simulations is presented. Based on a parameterized simulation model, tool temperatures, stresses and relative velocities can be calculated as a function of tool microgeometry. It can be shown that the external tool loads can be simulated with high agreement. With the help of these loads and the use of wear models, the resulting tool wear and the optimum cutting edge rounding can be determined. The final experimental investigations show a qualitatively high agreement to the simulation, which will enable a reduced effort design of the cutting edge in the future.

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Investigation on cutting edge preparation and FEM assisted optimization of the cutting edge micro shape for machining of nickel-base alloy

Cited by 15 publications

References 17 publications

Optimal fabrication of a thin-film thermocouple (TFTC) using Alumel/chromel junctions

Optimal fabrication of a thin-film thermocouple (TFTC) using Alumel/chromel junctions

A Numerical Model for Predicting the Effect of Tool Nose Radius on Machining Process Performance during Orthogonal Cutting of AISI 1045 Steel

FE-Simulation Based Design of Wear-Optimized Cutting Edge Roundings

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