Numerical Modeling of Cutting Forces and Temperature Distribution in High Speed Cryogenic and Flood-cooled Milling of Ti-6Al-4V

Caudill, J.; Schoop, Julius; Jawahir, I.S.

doi:10.1016/j.procir.2019.04.055

Cited by 22 publications

(10 citation statements)

References 22 publications

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“…However, the X-Y plots in Figure 2 to Figure 5 demonstrated that in both halfimmersions, the trend-lines of cutting force components and resultant force had fluctuated as the spindle speed increased from 13300 rpm to 37600 rpm at constant chip loads of 0.013 mm/tooth, 0.016 mm/tooth and 0.019 mm/tooth. Thus it can be claimed that the behaviour of cutting force when the spindle speed increased at the constant chip load is quadratic instead of linear, as previously mentioned in [11][12][13][14][15], where cutting force is defined in a linear relationship with respect to the spindle speed. Besides, the cutting force components and resultant force have quadratic behaviour.…”

Section: Resultsmentioning

confidence: 90%

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Effect of Increasing Spindle Speed at a Constant Chip Load on Cutting Force Behaviour of Hastelloy X

Nor¹,

Baharudin²,

Ghani³

et al. 2021

IJAME

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Cutting force is vital in machining nickel-based superalloys due to their excellent mechanical properties, thus creating difficulty in cutting. In the current scenario of metal machining, milling processes require high spindle speed and low chip load, which result in a low cutting force. However, low chip load not only result in low cutting force but also result in a low material removal rate (MRR). It is contrary to the ultimate high-speed machining (HSM) goal, which is to improve productivity and cost-effectiveness. Therefore, the emergence of an approach for achieving simultaneous low cutting force and high MRR is crucial. This paper presents the effect of increasing spindle speed at a constant chip load on the cutting force of Hastelloy X during half-immersion up-milling and half-immersion down-milling. In both half-immersions, the simulation results and experimental results are in good agreement. The percentage contribution of feed force, normal force and axial force to the resultant force can be arranged descendingly from high to low as axial force > normal force > axial force. Moreover, feed force, normal force, axial force and resultant force have a U-shaped behaviour. The spindle speed of 24,100 rpm and a chip load of 0.019 mm/tooth were found to achieve both low cutting force and high MRR.

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Section: Resultsmentioning

confidence: 90%

“…Meanwhile, research on cutting force stated that a decrease in cutting force coincides with an increase in cutting speed [11][12][13][14][15]. This is attributed to the generation of higher cutting temperature in the shear zone, which soften the machined material owing to a drop in its mechanical properties [13,14].…”

Section: Introductionmentioning

confidence: 99%

Effect of Increasing Spindle Speed at a Constant Chip Load on Cutting Force Behaviour of Hastelloy X

Nor¹,

Baharudin²,

Ghani³

et al. 2021

IJAME

View full text Add to dashboard Cite

show abstract

“…For example, different nose radii influence the cutting forces generated during machining. If these radii are smaller, then the cutting forces generated will be higher [26,27]. The study carried out by Yameogo et al [28] presents a method for the prediction of cutting forces and chip morphology by using a 2D FE model.…”

Section: Cutting Force Prediction Methodsmentioning

confidence: 99%

Cutting Forces Assessment in CNC Machining Processes: A Critical Review

Sousa

Silva

Fecheira

et al. 2020

Sensors

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Machining processes remain an unavoidable technique in the production of high-precision parts. Tool behavior is of the utmost importance in machining productivity and costs. Tool performance can be assessed by the roughness left on the machined surfaces, as well as of the forces developed during the process. There are various techniques to determine these cutting forces, such as cutting force prediction or measurement, using dynamometers and other sensor systems. This technique has often been used by numerous researchers in this area. This paper aims to give a review of the different techniques and devices for measuring the forces developed for machining processes, allowing a quick perception of the advantages and limitations of each technique, through the literature research carried out, using recently published works.

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“…This means that cutting force data provide a way to monitor the process or identify certain aspects that can be improved in the machining process. The knowledge of these cutting forces can be used to monitor tool behavior [34,35] and give information on optimal machining parameters [36,37], thus enabling the improvement of the machining process, either by parameter optimization, by improving tool life or even by helping with the development of new machining tool technology [38,39]. There are different methods for determining cutting forces, either by using a direct or indirect approach [40][41][42][43].…”

Section: Introductionmentioning

confidence: 99%

Investigations on the Wear Performance of Coated Tools in Machining UNS S32101 Duplex Stainless Steel

Sousa

Silva

Alexandre³

et al. 2022

Metals

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Due to their high mechanical property values and corrosion resistance, duplex stainless steels (DSSs) are used for a wide variety of industrial applications. DSSs are also selected for applications that require, especially, high corrosion resistance and overall good mechanical properties, such as in the naval and oil-gas exploration industries. The obtention of components made from these materials is quite problematic, as DSSs are considered difficult-to-machine alloys. In this work, the developed wear during milling of the UNS S32101 DSS alloy is presented, employing four types of milling tools with different geometries and coatings. The influence of feed rate and cutting length variations on the tools’ wear and their performance was evaluated. The used tools had two and four flutes with different coatings: TiAlN, TiAlSiN and AlCrN. The cutting behavior of these tools was analyzed by collecting data regarding the cutting forces developed during machining and evaluating the machined surface quality for each tool. After testing, the tools were submitted to SEM analysis, enabling the identification of the wear mechanisms and quantification of flank wear, as well as identifying the early stages of the development of these mechanisms. A comparison of all the tested tools was made, determining that the TiAlSiN-coated tools produced highly satisfactory results, especially in terms of sustained flank wear.

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Numerical Modeling of Cutting Forces and Temperature Distribution in High Speed Cryogenic and Flood-cooled Milling of Ti-6Al-4V

Cited by 22 publications

References 22 publications

Effect of Increasing Spindle Speed at a Constant Chip Load on Cutting Force Behaviour of Hastelloy X

Effect of Increasing Spindle Speed at a Constant Chip Load on Cutting Force Behaviour of Hastelloy X

Cutting Forces Assessment in CNC Machining Processes: A Critical Review

Investigations on the Wear Performance of Coated Tools in Machining UNS S32101 Duplex Stainless Steel

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