Prediction model of surface residual stress within a machined surface by combining two orthogonal plane models

Sasahara, Hiroyuki; Obikawa, Toshiyuki; Shirakashi, Takahiro

doi:10.1016/j.ijmachtools.2004.01.002

Cited by 71 publications

(40 citation statements)

References 12 publications

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“…Increasing the ploughing effect leads to more material side flow on the machined surface. A large nose radius results in to generation of compressive residual stress beneath the machined surface 48 .…”

Section: Effect Of Nose Radiusmentioning

confidence: 99%

Analysis of surface roughness and hardness in titanium alloy machining with polycrystalline diamond tool under different lubricating modes

Revankar¹,

Shetty

Rao

et al. 2014

Mat. Res.

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The present work deals with the investigation on machining of difficult-to-machine material titanium alloy (Ti-6Al-4V) using poly crystalline diamond (PCD) tool under different coolant strategies, namely dry, flooded and MQL. Taguchi technique has been employed and the optimization results indicated that MQL lubricating mode with cutting speed of 150 m/min, feed rate of 0.15 mm/rev, nose radius of 0.6 mm and 0.25 mm depth of cut is necessary to minimize surface roughness and dry mode with cutting speed of 150 m/min, feed rate of 0.15 mm/rev, nose radius of 0.6 mm and 0.75 mm depth of cut is necessary to maximize surface hardness. The results indicate the substantial benefit of the minimum quantity of lubrication (MQL) and justify PCD inserts to be the most functionally satisfactory commercially available cutting tool material for machining titanium alloys for better surface finish and hardness.

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Section: Effect Of Nose Radiusmentioning

confidence: 99%

Analysis of surface roughness and hardness in titanium alloy machining with polycrystalline diamond tool under different lubricating modes

Revankar¹,

Shetty

Rao

et al. 2014

Mat. Res.

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“…Komanduri and Hou [12] reported that catastrophic tool failure through chipping is caused by pulsating loads from plastic deformation in the shear bands between the chip segments, self-induced chatter, and fluctuating cutting forces produced during the milling operation. Efficient cutting strategies and parameters therefore play a critical role in managing the tool engagement and demands imposed as a result.…”

Section: Machining Challengesmentioning

confidence: 99%

“…It is important, therefore, to understand the effect of changing parameters on different aspects of surface integrity. This is a well-researched area, and much work has been done to encompass a great variety of approaches and techniques to determine the state of the material after manufacture [4,5,7,8,12]. In general, it involves investigating the surface roughness, metallurgical changes, micro-hardness, and the residual stresses of the machined work piece [13].…”

Section: Machining Challengesmentioning

confidence: 99%

The Effect of Cutting Parameters on Surface Integrity in Milling Ti6al4v

Oosthuizen

Nunco

Conradie

et al. 2016

SAJIE

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The objective of machining performance is to reduce operational costs and to increase the production rate while maintaining or improving the required surface integrity of the machined component. Together with industrial partners, several benchmark titanium components were selected and machined to achieve this. Titanium alloys are used extensively in several industries due to its unique strength-to-weight ratio and corrosion resistance. Its properties, however, also make it susceptible to surface integrity damage during machining operations. The research objectives of this study were to understand the effect of cutting parameters on surface integrity to ensure that machined components are within the required surface quality tolerances. The effect of cutting speed and feed rate on surface roughness, micro-hardness, and the microstructure of the work piece were studied for milling Ti6Al4V. The surface roughness increased with a greater feed rate and a decrease in cutting speed. The maximum micro-hardness was 23 per cent harder than the bulk material. Plastic deformation and grain rotation below the machined surface were found with the rotation of the grain lines in the direction of feed. There was no evidence of subsurface defects for any of the cutting conditions tested. OPSOMMINGDie masjineringsvermoë doelwit bly steeds om operasionele kostes te verminder en om die produksietempo te verhoog, terwyl die vereiste oppervlakafwerking van die komponent gehandhaaf of verbeter word. Ten einde hierdie doelstelling te bereik is verskeie komponente in samewerking met industrievennote, as maatstaaf komponente gekies en gemasjineer. Titaan allooie word op groot skaal in verskeie industrieë gebruik vanweë sy unieke sterkte-totdigtheid verhouding en korrosiebestandheid. Hierdie eienskappe maak die allooi egter ook vatbaar vir oppervlakafwerking skade tydens die masjineringsproses. Die navorsingsdoelstelling van hierdie studie was om die effek van die snyparameters op die oppervlakafwerking te verstaan, om sodoende te verseker dat die komponente binne die vereiste oppervlak toleransies vervaardig word. Die effek van snyspoed en voertempo tydens freeswerk op die oppervlak grofheid, mikrohardheid en mikrostruktuur van die Ti6Al4V werkstuk is bestudeer. Die oppervlakgrofheid het verhoog met 'n toename in voertempo en vermindering in snyspoed. Die maksimum mikrohardheid was 23 persent harder as die basismateriaal. Plastiese vervorming en korrel rotasie onder die gemasjineerde werkstuk oppervlak is gevind met die korrelgrein in die rigting van die voer. Daar was geen aanduiding van suboppervlak defekte onder enige van die toets kondisies nie.

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“…Hence a large edge radius has a similar effect to a negative rake angle i.e. to generate compressive residual stress beneath the machined surface [42].…”

Section: Dograv S Sharma J Dureja / Journal Of Engineering Scmentioning

confidence: 99%

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2011

JESTR

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The effect of cutting tool geometry has long been an issue in understanding mechanics of turning. Tool geometry has significant influence on chip formation, heat generation, tool wear, surface finish and surface integrity during turning. This article presents a survey on variation in tool geometry i.e. tool nose radius, rake angle, groove on the rake face, variable edge geometry, wiper geometry and curvilinear edge tools and their effect on tool wear, surface roughness and surface integrity of the machined surface. Further modeling and simulation approaches on tool geometry including one approach developed in a recent study, on variable micro-geometry tools, is discussed in brief.Keywords: Curvilinear edge, rake angle, grooved tools, nose radius, variable geometry. Stringent control on the quality of machined surface and sub-surface during turning is most important consideration a part from considering the tool life. In order to attain sufficiently high production rates at minimum cost, optimization of cutting tool geometry is necessary [1], [2]. The design of cutting edge geometry and its influence on machining performance have been a research topic in metal cutting for a long time. Edge preparation has a critical effect on the tool life. A tool with poor edge preparation may chip and fail quickly [3]. Users expect to have more and more productivity in their machining processes (high removal rate of work-material) and low wear of their cutting tools (long tool life). These demands require major improvements in the design of cutting tools: new substrates, new coatings, cutting tool geometry and materials etc. According to tool manufacturers, the manufacturing procedures of their cutting tools, especially the micro-geometry preparation (cutting edge etc.), have a major influence on their performance and on their reliability [4]. Edge preparation must be carefully selected for a given application because it affects the surface integrity of the machined workpiece (white layer, residual stresses etc.) [5]. Heat generated during hard turning is also affected by edge preparation due to change in work material flow around the cutting edge. For example, a chamfered face provides excessive negative angle to the cutting action and results in high heat generation. PCBN tools rapidly wear out during hard turning at high cutting speeds mainly due to attained temperatures [6].It is important to consider the tool-edge effect in order to better understand the chip formation mechanism and accurately predict machining performances, such as cutting forces, cutting temperatures, tool wear, surface finish and the machined surface integrity. The methods commonly employed include experimental, analytical, and numerical methods [7]. The tool geometry effects on turning performance parameters are mentioned in Figure1.It is demonstrated that the cutting tool edge geometry significantly influences many fundamental aspects such as cutting forces, chip formation, cutting temperature, tool wear, tool-life and characteristics like sur...

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Prediction model of surface residual stress within a machined surface by combining two orthogonal plane models

Cited by 71 publications

References 12 publications

Analysis of surface roughness and hardness in titanium alloy machining with polycrystalline diamond tool under different lubricating modes

Analysis of surface roughness and hardness in titanium alloy machining with polycrystalline diamond tool under different lubricating modes

The Effect of Cutting Parameters on Surface Integrity in Milling Ti6al4v

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