Micro-dimple pattern process and orthogonal cutting force analysis of elliptical vibration texturing

Kurniawan, Rendi; Kiswanto, Gandjar; Ko, Tae Jo

doi:10.1016/j.ijmachtools.2016.03.007

Cited by 58 publications

(13 citation statements)

References 47 publications

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“…It not only reduces friction but also serves to achieve environmentally conscious manufacturing [8]. Different researchers used different methods to engrave texture on cutting tool such as wire-electric discharge machining (WEDM) [9,10], laser texturing [11,12], mechanical base texturing [13], ultrasonic and electrical vibration texturing [14]. Obikawa et al [15] reported parallel grooves reduced the frictional force between chip and tool that could be significant than the perpendicular grooves to the cutting edge.…”

Section: Introductionmentioning

confidence: 99%

Performance of textured tool in turning of Ti–6Al–4V alloy: numerical analysis and experimental validation

Parida

Rao

Ghosh

2020

J Braz. Soc. Mech. Sci. Eng.

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Development of advanced or new cutting tool has gained attention among the research community nowadays. Due to environmental obligation, researchers are working on hybrid machining processes without cutting fluids to improve sustainability. The effect of micro-dimple-textured tool on turning of Ti-6Al-4V alloy is assessed by considering cutting force, chip morphology and chip flow angle using finite element method (FEM) in the current study. The machining simulations are performed for both flat and textured tool using DEFORM software. The simulation results show that machinability of textured tool increased (maximum reduction 16, 30 and 12% in cutting surface roughness and chip thickness, respectively) as compared to the flat tool. The simulated results are validated by performing experimental runs, and significant coherence (error % < 10) is obtained.

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Section: Introductionmentioning

confidence: 99%

Performance of textured tool in turning of Ti–6Al–4V alloy: numerical analysis and experimental validation

Parida

Rao

Ghosh

2020

J Braz. Soc. Mech. Sci. Eng.

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“…9 It has been proved that this periodically interrupted cutting process could positively be effective on cutting performance such as tool life, surface roughness, chatter condition, etc. [10][11][12] However, investigation of shear angle and sticky region in the ultrasonic-assisted turning (UAT) was rarely carried out. On the other hand, covering all aspects of cutting process in theoretical and experimental works may not adequately be practicable due to general complexity of metal cutting process.…”

Section: Introductionmentioning

confidence: 99%

Theoretical and numerical modeling of tool–chip friction in ultrasonic-assisted turning

Lotfi

Amini

Ashrafi

2018

Proceedings of the Institution of Mechanical Engineers, Part E:

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Decrease of friction in tool–chip contact zone is a key subject in metal cutting operation. Therefore, effect of ultrasonic vibration in this area is analyzed by using experimental and simulation methods. In this study, a theoretical model is firstly developed based on the shear friction model, and then sticking–sliding contact zones plus their contact lengths are defined in order to simulate conventional and ultrasonic-assisted turning. Accordingly, shear angle, sticky length, and cutting forces were measured in experiments as input parameters for the calculation of friction coefficients. As a result, intermittent contact of vibrated tool decreases the time of thermal conduction in tool–chip interface, resulting in a significant reduction in friction coefficient and contact length, particularly, in sticky region.

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“…3,4 2D UVAT was first introduced in 1993 by Shamoto and Moriwaki 5 and this process indicated further achievement in the reduction of cutting force and better machining accuracy. 6,7 On the other hand, turning of hard materials such as nickel-based super alloys commonly have some difficulties due to their rapid strain hardening, high strength and poor thermal conductivity. 8,9 In this case, conventional turning may not provide all benefits in the desired factors of machinability such as low cutting force, long tool life and mirror surface Enish.…”

Section: Introductionmentioning

confidence: 99%

FE simulation of linear and elliptical ultrasonic vibrations in turning of Inconel 718

Lotfi

Amini

2017

Proceedings of the Institution of Mechanical Engineers, Part E:

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Utilization of ultrasonic vibrations in turning operation is an advanced method to improve processing of materials. The aim of the present study was to develop a finite element model in order to investigate the effect of ultrasonic vibrations on machinability factors in turning of Inconel 718. Conventional turning in addition to linear and elliptical ultrasonicassisted turning were simulated and the effect of these processes on cutting forces, shear angle, chip thickness, sticky zone, and temperature distributed on tool rake face was analyzed. Besides, the experimental tests were conducted and the cutting forces have been measured to validate the simulation outputs. As a result, analysis of chip formation shows that the values higher than 45 for shear angle is achieved when elliptical vibration is added to the cutting process. Furthermore, increase of shear angle coupled with decrease of temperature on tool rake face causes the sticky zone in tool-chip contact length to be reduced compared to the conventional turning. Moreover, the influence of cutting speed on tool-chip engagement time in ultrasonic-assisted turning is simulated.

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Micro-dimple pattern process and orthogonal cutting force analysis of elliptical vibration texturing

Cited by 58 publications

References 47 publications

Performance of textured tool in turning of Ti–6Al–4V alloy: numerical analysis and experimental validation

Performance of textured tool in turning of Ti–6Al–4V alloy: numerical analysis and experimental validation

Theoretical and numerical modeling of tool–chip friction in ultrasonic-assisted turning

FE simulation of linear and elliptical ultrasonic vibrations in turning of Inconel 718

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