Mechanistic Model for Prediction of Cutting Forces in Turning of Non-axisymmetric Parts

Cascón, Itxaso; Sarasua, Jon Ander

doi:10.1016/j.procir.2015.03.084

Cited by 11 publications

(3 citation statements)

References 14 publications

(15 reference statements)

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“…However, reducing cutting edge angle also leads to the rise of temperatures and to excessively thin chips that accelerate tool wear. Cascón et al [8] proposed a force prediction model from CAM simulations along the machining path of non-symmetric parts. In order to mitigate the effects of intermittent hitting, the possibility of reducing cutting edge angle was explored.…”

Section: Introductionmentioning

confidence: 99%

On the effects of cutting-edge angle on high-feed turning of Inconel 718© superalloy

Amigo

Urbikaín²,

Lacalle³

et al. 2023

Int J Adv Manuf Technol

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Machining processes on heat-resistant superalloys—i.e., turbine cases, rings, or shafts—are challenging tasks. The high-added value of such parts makes cycle times be longer than expected. Recently, high-feed turning technique has attracted the attention of practitioners due to its high material removal rate capability. PrimeTurning™ tool unifies the concepts of high-feed and multidirectional turning using multiple active cutting edges. It should be capable of reducing machine downtimes in that kind of parts. However, to avoid early tool replacement and rejects on high added value parts, a deeper knowledge on the high-feed turning process is necessary. Here, inserts specifically designed for high-feed turning in heat resistant Inconel 718© alloy were tested using three cutting-edge angles. The results showed that when chip thickness is more relevant, a cutting-edge angle of 30° reduces the likelihood of notches. Even if force components are high, surface roughness is improved and the risk of fractures is minimized, together with a high evacuation volume. On the other hand, increasing the cutting-edge angle (45° and 60°) without compensating the feed rate, tends to produce tool fractures due to chip overload. Besides, experimental tests showed that long tool-to-workpiece contact times, tend to shorten tool life, due to excessive heat accumulation and poor chip control.

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Section: Introductionmentioning

confidence: 99%

On the effects of cutting-edge angle on high-feed turning of Inconel 718© superalloy

Amigo

Urbikaín²,

Lacalle³

et al. 2023

Int J Adv Manuf Technol

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“…From that figure, it can be observed that the cutting force has higher values than passive and feed forces, and both of the torque and the power have a periodic nature. That is due to lead angle effect which is considered as a determinant factor in interrupted turning due to the intermittent hitting [73]. Figure 5 plotted the effect of different investigated factors (coating condition, nose radius, cutting speed, feed rate, and cutting depth) on the resultant force as well as the force components.…”

Section: Cutting Forcesmentioning

confidence: 99%

Effect of cutting parameters on surface residual stresses in dry turning of AISI 1035 alloy

Salman

Elsheikh

Ashham

et al. 2019

J Braz. Soc. Mech. Sci. Eng.

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Residual stresses (RSes) induced by turning processes have a great effect on the material properties of the machined components and their abilities to withstand severe loading conditions (creep, fatigue, and stress corrosion cracking). The final state of RSes in a workpiece depends on its material and on the employed cutting parameters/conditions such as cutting speed, depth of cut, feed speed, cutting tool geometry, wear of the tool, cutting tool geometry, cutting tool coating, and cooling. This study introduces a comprehensive investigation of the effects of different cutting parameters, such as cutting speed (30, 60, and 90 m/min), feed (0.05, 0.1, and 0.3 mm/rev), and depth of cut (0.1, 0.5, and 1 mm) as well as cutting tool geometry such as cutting tool nose radius (0.397, 0.794, and 1.191 mm), and cutting tool coating (coated and uncoated) on the cutting force, maximum cutting temperature, surface microstructure, and surface residual stresses during cutting AISI 1035 alloy steel. The RSes were measured using X-ray diffraction technique. The experiments were designed using Taguchi method based on L 18 orthogonal array, and the significance level of different cutting parameters as well as cutting tool properties have been determined via applying analysis of variance. Numerical simulations have been carried out using commercial machining software AdvantEdge.

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“…Numerous developments in numerical methods and simulations associated with the existence of increasingly powerful computers make it possible to study tool wear using FEM. Modeling issues are addressed by considering microstructures as homogeneous characteristics and corresponding verification methods [13][14][15][16][17][18][19][20].…”

Section: Introductionmentioning

confidence: 99%

Study of a Methodology for Calculating Contact Stresses during Blade Processing of Structural Steel

Kozlov,

Babaev,

Schulz

et al. 2023

Metals

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The article presents data about the distribution of contact stresses on the rake surface of the cutter when turning steel (Fe-0.4 C-1Cr), which were obtained by the split cutter method. The article also provides graphs of the effect of the uncut chip thickness a and the rake angle γ on the main parameters of the plots of shear τ and normal σ contact stresses. For this case, The initial data were obtained by longitudinal turning of a steel workpiece with the measurement of the technological components of the cutting force by a three-component Kistler dynamometer, followed by the calculation of the physical components of the cutting force. The rake angle varied widely, from +35 to −10°, and the uncut chip thickness a varied from 0.05 to 0.37 mm. A decrease in the rake angle from +35 to −10° leads to a significant increase in the maximum normal contact stress at the cutting edge σmax: from 400 to 1400 MPa with the uncut chip thickness a = 0.37 mm. In the area of small uncut chip thickness, a (less than 0.1 mm), the paradoxical increase in the magnitude of the greatest normal contact stress with a large positive rake angle (more than +15°) is explained by the indentation (pressing) of the being machined material under the rounded cutting edge of the cutter in the chip formation zone, and their paradoxical decrease with a negative rake angle is due to the presence of a sag (deflection) of the transient surface. According to the magnitude of the reference points obtained on the basis of experimental data, it is possible to plot the contact stresses epures on the rake surface of the cutting tools when machining steel.

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Mechanistic Model for Prediction of Cutting Forces in Turning of Non-axisymmetric Parts

Cited by 11 publications

References 14 publications

On the effects of cutting-edge angle on high-feed turning of Inconel 718© superalloy

On the effects of cutting-edge angle on high-feed turning of Inconel 718© superalloy

Effect of cutting parameters on surface residual stresses in dry turning of AISI 1035 alloy

Study of a Methodology for Calculating Contact Stresses during Blade Processing of Structural Steel

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