Practical applications of the “energy–triaxiality” state relationship in metal cutting

Abushawashi, Yalla; Xiao, Xinran; Astakhov, Viktor P.

doi:10.1080/10910344.2015.1133913

Cited by 18 publications

(7 citation statements)

References 12 publications

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“…In (Istotskiy and Protas'ev, 2006;Protas'ev and Istotskiy, 2011;Istotskiy and Protasev, 2017) provides the features of the design, construction and operation of tools, including screw backing, and the above information indicates the expansion of sustainable exploitation tools with screw backing. Modern tool production at the stage of its preparation is unthinkable without the formation of a technological 3D model (Ni, 2006;Istotskiy and Protas'ev, 2007;Pham and Ko, 2010), obtained using a virtual analogue of the grinding and grinding machine, where it is formed using the principles of Boolean algebra (Abushawashi et al, 2017). The result of this simulation using the calculations performed above is shown in Figure 3.…”

Section: Analysis Of the Resultsmentioning

confidence: 99%

Design and Manufacture of Hob Mills for the Formation of Straight Slots Using the Principles of Screw Backing

Istotskiy¹,

Protasev²

2019

Int J Math, Eng, Manag Sci

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The article shows the possibility of designing and manufacturing using multi-coordinate grinding and sharpening machines with CNC for workable worm mills for machining straight-slotted slots. Screw backing provides the necessary values of the rear side corners, and the ability of CNC machines to achieve the required accuracy and manufacturability of the tool. The lack of such tools consists in the increase of the diametrical sizes in comparison with the classically used ones. A positive effect when using the principles of screw backlash is the shaping of the cutting edges of the teeth in a checkerboard pattern, which significantly reduces the cutting forces. The use of techno-logical 3D models as a result of the design allows, at the design stage, to evaluate the arising design flaws and to make the necessary corrective actions into the initial data of the tool.

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Section: Analysis Of the Resultsmentioning

confidence: 99%

Design and Manufacture of Hob Mills for the Formation of Straight Slots Using the Principles of Screw Backing

Istotskiy¹,

Protasev²

2019

Int J Math, Eng, Manag Sci

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“…An adequate selection of the constitutive model and related calibration methodologies can significantly influence the quality of the numerical estimates. The accuracy of the numerical models increases with the range and combination of the triaxiality and Lode angle considered in the inverse calibration procedures [21]. The above mentioned direct characterization and inverse calibration methodologies are expected to provide accurate input data parameters for the numerical simulation of the metal cutting processes [22].…”

Section: Efficient Methodology For Constitutive Modelling Calibrationmentioning

confidence: 99%

An Efficient Methodology towards Mechanical Characterization and Modelling of 18Ni300 AMed Steel in Extreme Loading and Temperature Conditions for Metal Cutting Applications

Silva

Gregório

Jesus

et al. 2021

JMMP

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A thorough control of the machining operations is essential to ensure the successful post-processing of additively manufactured components, which can be assessed through machinability tests endowed with numerical simulation of the metal cutting process. However, to accurately depict the complex metal cutting mechanism, it is not only necessary to develop robust numerical models but also to properly characterize the material behavior, which can be a long-winded process, especially for state-of-stress sensitive materials. In this paper, an efficient mechanical characterization methodology has been developed through the usage of both direct and inverse calibration procedures. Apart from the typical axisymmetric specimens (such as those used in compression and tensile tests), plane strain specimens have been applied in the constitutive law calibration accounting for plastic and damage behaviors. Orthogonal cutting experiments allowed the validation of the implemented numerical model for simulation of the metal cutting processes. Moreover, the numerical simulation of an industrial machining operation (longitudinal cylindrical turning) revealed a very reasonably prediction of cutting forces and chip morphology, which is crucial for the identification of favorable cutting scenarios for difficult-to-cut materials.

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“…Therefore, factors affecting the fracture strain, such as state of stress (stress triaxiality and Lode parameter), strain rate, and temperature, also affect metal cutting results (forces, temperatures, CCR, surface integrity, etc.) [39][40][41]. The graphical representations of the influence of the cutting parameters on the F c and F t forces are shown in Figures 6 and 7.…”

Section: Cutting and Thrust Forcesmentioning

confidence: 99%

Section: Cutting and Thrust Forcesmentioning

confidence: 99%

Modelling and Optimization of Machining of Ti-6Al-4V Titanium Alloy Using Machine Learning and Design of Experiments Methods

Outeiro

Cheng

Chinesta

et al. 2022

JMMP

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Ti-6Al-4V titanium is considered a difficult-to-cut material used in critical applications in the aerospace industry requiring high reliability levels. An appropriate selection of cutting conditions can improve the machinability of this alloy and the surface integrity of the machined surface, including the generation of compressive residual stresses. In this paper, orthogonal cutting tests of Ti-6Al-4V titanium were performed using coated and uncoated tungsten carbide tools. Suitable design of experiments (DOE) was used to investigate the influence of the cutting conditions (cutting speed Vc, uncut chip thickness h, tool rake angle γn, and the cutting edge radius rn) on the forces, chip compression ratio, and residual stresses. Due to the time consumed and the high cost of the residual stress measurements, they were only measured for selected cutting conditions of the DOE. Then, the machine learning method based on mathematical regression analysis was applied to predict the residual stresses for other cutting conditions of the DOE. Finally, the optimal cutting conditions that minimize the machining outcomes were determined. The results showed that when increasing the compressive residual stresses at the machined surface by 40%, the rake angle should be increased from negative (−6°) to positive (5°), the cutting edge radius should be doubled (from 16 µm to 30 µm), and the cutting speed should be reduced by 67% (from 60 to 20 m/min).

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Practical applications of the “energy–triaxiality” state relationship in metal cutting

Cited by 18 publications

References 12 publications

Design and Manufacture of Hob Mills for the Formation of Straight Slots Using the Principles of Screw Backing

Design and Manufacture of Hob Mills for the Formation of Straight Slots Using the Principles of Screw Backing

An Efficient Methodology towards Mechanical Characterization and Modelling of 18Ni300 AMed Steel in Extreme Loading and Temperature Conditions for Metal Cutting Applications

Modelling and Optimization of Machining of Ti-6Al-4V Titanium Alloy Using Machine Learning and Design of Experiments Methods

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