Pub Date : 2021-07-04DOI: 10.1080/10910344.2021.1903922
S. M. Ebrahimi, M. Hadad, A. Araee
Abstract The main objective of this study is to initially simulate the cutting process of hardened AISI630 stainless steel to implement thermally enhanced turning followed by hot turning (HT) experiments to demonstrate the effectiveness of the process and identify cutting parameters that would yield the optimum results in terms of sustainability. To precisely predict the chip morphology, as well as the cutting force and tool temperature, 2 D and 3 D FEM analysis, have been used, respectively using AdvantEdge software. The numerical analysis showed that HT in 300 °C causes a reduction of 28% in cutting forces. The tool wear in HT reduces up to 33% in comparison to conventional turning (CT). Furthermore, the relation between cutting force fluctuation and the machined surface roughness has been investigated applying numerical analysis and experimental data. The results revealed that HT in 300 °C reduces the machined surface roughness up to 23%. In addition, it has been observed that HT technique decreases side flow and surface damages in comparison to CT.
{"title":"Sustainable machining of hardened AISI630 stainless steel using thermally enhanced turning technique","authors":"S. M. Ebrahimi, M. Hadad, A. Araee","doi":"10.1080/10910344.2021.1903922","DOIUrl":"https://doi.org/10.1080/10910344.2021.1903922","url":null,"abstract":"Abstract The main objective of this study is to initially simulate the cutting process of hardened AISI630 stainless steel to implement thermally enhanced turning followed by hot turning (HT) experiments to demonstrate the effectiveness of the process and identify cutting parameters that would yield the optimum results in terms of sustainability. To precisely predict the chip morphology, as well as the cutting force and tool temperature, 2 D and 3 D FEM analysis, have been used, respectively using AdvantEdge software. The numerical analysis showed that HT in 300 °C causes a reduction of 28% in cutting forces. The tool wear in HT reduces up to 33% in comparison to conventional turning (CT). Furthermore, the relation between cutting force fluctuation and the machined surface roughness has been investigated applying numerical analysis and experimental data. The results revealed that HT in 300 °C reduces the machined surface roughness up to 23%. In addition, it has been observed that HT technique decreases side flow and surface damages in comparison to CT.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"608 - 636"},"PeriodicalIF":2.7,"publicationDate":"2021-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1080/10910344.2021.1903922","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49211764","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-07-04DOI: 10.1080/10910344.2021.1925295
Chuangchuang Yuan, A. Pramanik, A. Basak, C. Prakash, Subramaniam Shankar
Abstract In recent years, demand of titanium alloy (Ti6Al4V) in various industries especially aerospace industries drastically increased. Several exceptional properties of titanium alloy that contribute to its popularity include high compressive and tensile strength, fracture toughness oxidation resistance and high strength-to-weight ratio. However, due to these superior properties, titanium alloys are categorized as hard-to-machine materials. The drilling process is accounted for roughly 40%−60% of material removal processes of an aeronautical product. Drilling processes for titanium alloys are categorized into conventional method (twist drilling) and unconventional method (rotary ultrasonic machining [RUM] drilling, laser drilling and electron discharge machining [EDM] drilling). This research aims to identify mechanisms and limitations of each drilling method applicable on titanium alloys. In addition, processing parameters affecting performance measures of each drilling method are discussed. The main problem associated with conventional twist drilling is extreme processing temperature, resulting in rapid tool wear and extensive burrs formation. These issues cause the cost for titanium alloy drilling to be relatively high as compared with twist drilling of other materials. To minimize these issues, researchers have developed several unconventional drilling methods, aiming to minimize issues found in conventional twist drilling.
{"title":"Drilling of titanium alloy (Ti6Al4V) – a review","authors":"Chuangchuang Yuan, A. Pramanik, A. Basak, C. Prakash, Subramaniam Shankar","doi":"10.1080/10910344.2021.1925295","DOIUrl":"https://doi.org/10.1080/10910344.2021.1925295","url":null,"abstract":"Abstract In recent years, demand of titanium alloy (Ti6Al4V) in various industries especially aerospace industries drastically increased. Several exceptional properties of titanium alloy that contribute to its popularity include high compressive and tensile strength, fracture toughness oxidation resistance and high strength-to-weight ratio. However, due to these superior properties, titanium alloys are categorized as hard-to-machine materials. The drilling process is accounted for roughly 40%−60% of material removal processes of an aeronautical product. Drilling processes for titanium alloys are categorized into conventional method (twist drilling) and unconventional method (rotary ultrasonic machining [RUM] drilling, laser drilling and electron discharge machining [EDM] drilling). This research aims to identify mechanisms and limitations of each drilling method applicable on titanium alloys. In addition, processing parameters affecting performance measures of each drilling method are discussed. The main problem associated with conventional twist drilling is extreme processing temperature, resulting in rapid tool wear and extensive burrs formation. These issues cause the cost for titanium alloy drilling to be relatively high as compared with twist drilling of other materials. To minimize these issues, researchers have developed several unconventional drilling methods, aiming to minimize issues found in conventional twist drilling.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"637 - 702"},"PeriodicalIF":2.7,"publicationDate":"2021-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1080/10910344.2021.1925295","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48623362","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-05-18DOI: 10.1080/10910344.2021.1903925
Gaurav Bhakar, Pratik Khandagale, H. Sonawane, S. Joshi
Abstract The uncertainty in the prediction of machining stability increases with the increasing flexibility of the workpiece. The past research showed that the process cannot be stabilized even using the largest pockets in the stability diagrams due to high flexibility of the parts. Therefore, the present research emphasizes extensive experimental analysis where the uncertainty of the stability lobe diagrams was brought into the light, especially in the case of machining of flexible parts. This led to the introduction of a new term “Stability Region Diagram (SRD)” in the present research. The three generalized machining scenarios for chatter-free machining of thin-walled features on low rigidity Ti-6Al-V4 were experimentally analyzed. These include Scenario-I, where workpieces have identical pre-machining stiffness and natural frequency that varies during and after machining. In Scenario-II, workpiece stiffness and natural frequencies vary initially but are identical after machining. In Scenario-III, workpieces have identical pre-machining stiffness and natural frequency but vary during and after machining over central 1/3 part, straddled between bosses. Various machining strategies with an optimum combination of cutting speed-feed-radial depth of cut were developed using stability region diagrams (SRD) to achieve stable machining throughout the length of the cut along the flexible workpiece surface. For Scenario-I and II, stable machining is possible at widths of cut lesser than or equal to the final thickness of workpiece and at a constant spindle speed of 4,000 rpm throughout the length of the workpiece. However, while machining at widths of cut more than the post-machining thickness of the workpiece, the stable machining is possible using a spindle speed ramp-up technique. In the Scenario-III, the surrounding uncut material is found to make machining unstable which can be improved by spindle speed ramp-down technique.
{"title":"Strategy development for chatter-free milling of Ti-6Al-4V thin-walled surfaces using stability region diagram (SRD)","authors":"Gaurav Bhakar, Pratik Khandagale, H. Sonawane, S. Joshi","doi":"10.1080/10910344.2021.1903925","DOIUrl":"https://doi.org/10.1080/10910344.2021.1903925","url":null,"abstract":"Abstract The uncertainty in the prediction of machining stability increases with the increasing flexibility of the workpiece. The past research showed that the process cannot be stabilized even using the largest pockets in the stability diagrams due to high flexibility of the parts. Therefore, the present research emphasizes extensive experimental analysis where the uncertainty of the stability lobe diagrams was brought into the light, especially in the case of machining of flexible parts. This led to the introduction of a new term “Stability Region Diagram (SRD)” in the present research. The three generalized machining scenarios for chatter-free machining of thin-walled features on low rigidity Ti-6Al-V4 were experimentally analyzed. These include Scenario-I, where workpieces have identical pre-machining stiffness and natural frequency that varies during and after machining. In Scenario-II, workpiece stiffness and natural frequencies vary initially but are identical after machining. In Scenario-III, workpieces have identical pre-machining stiffness and natural frequency but vary during and after machining over central 1/3 part, straddled between bosses. Various machining strategies with an optimum combination of cutting speed-feed-radial depth of cut were developed using stability region diagrams (SRD) to achieve stable machining throughout the length of the cut along the flexible workpiece surface. For Scenario-I and II, stable machining is possible at widths of cut lesser than or equal to the final thickness of workpiece and at a constant spindle speed of 4,000 rpm throughout the length of the workpiece. However, while machining at widths of cut more than the post-machining thickness of the workpiece, the stable machining is possible using a spindle speed ramp-up technique. In the Scenario-III, the surrounding uncut material is found to make machining unstable which can be improved by spindle speed ramp-down technique.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"899 - 929"},"PeriodicalIF":2.7,"publicationDate":"2021-05-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1080/10910344.2021.1903925","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42837317","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-05-04DOI: 10.1080/10910344.2021.1903921
Shen-Shun Ying, Shunqi Zhang, Lvgao Lin, Yangyu Wang, R. Schmidt
Abstract Broaching is very efficient for machining complex-shaped slots in turbine disks made of high thermal resistant super-alloys. However, large cutting forces and high thermal flux lead to high tool wear. To reduce the broaching forces, this paper proposes a vibration assisted broaching system, including the main components of a hydraulic horizontal internal broaching machine, an electrohydraulic vibration exciter, a 2-dimensional valve and a control unit. A force measuring structure and vibration signal acquisition module are designed and integrated into the system. By changing the frequency of the active vibration, cutting forces are obtained and analyzed by fast Fourier transformation method. The experimental results show that through the additional imposed vibration, static and dynamic broaching forces are significantly reduced.
{"title":"Experimental investigation on reduction of broaching forces by active external vibrations","authors":"Shen-Shun Ying, Shunqi Zhang, Lvgao Lin, Yangyu Wang, R. Schmidt","doi":"10.1080/10910344.2021.1903921","DOIUrl":"https://doi.org/10.1080/10910344.2021.1903921","url":null,"abstract":"Abstract Broaching is very efficient for machining complex-shaped slots in turbine disks made of high thermal resistant super-alloys. However, large cutting forces and high thermal flux lead to high tool wear. To reduce the broaching forces, this paper proposes a vibration assisted broaching system, including the main components of a hydraulic horizontal internal broaching machine, an electrohydraulic vibration exciter, a 2-dimensional valve and a control unit. A force measuring structure and vibration signal acquisition module are designed and integrated into the system. By changing the frequency of the active vibration, cutting forces are obtained and analyzed by fast Fourier transformation method. The experimental results show that through the additional imposed vibration, static and dynamic broaching forces are significantly reduced.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"438 - 454"},"PeriodicalIF":2.7,"publicationDate":"2021-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1080/10910344.2021.1903921","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49458014","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-05-04DOI: 10.1080/10910344.2021.1903923
Preeti Maurya, V. G. S., R. C., B. Shivamurthy
Abstract Elastomers have visco-elastic behavior and are widely used in general utility as well as sophisticated applications. Generally, elastomer components are produced by molding process. But it is not economical for complicated geometrical elastomeric components of small batch size. Hence, machining is an alternative method of the molding. However, high elasticity, low Young’s modulus and low thermal conductivity in addition to the difficulty of holding elastomer component hinder its machining. To address these challenges, in last two decades, cryogenic assisted milling/turning, cryogenic abrasive jet micromachining (CAJM), ultra-high-pressure water jet machining and low-power CO2 laser cutting were reported and noticed that both machining parameters and cryogenic condition affect the quality of the end-product. The structure-property changes on the surface of elastomer due to cryogenic condition helps in improvement of cutting force, erosion rate, chip formation, surface morphology, and reduction in the abrasive particle embedding at the machined surface. In addition to this, cryogenic assisted machining is a safe environmental alternative approach and it reduces the possibility of abrasive contamination at the machined surface. Hence, this article makes a comprehensive review of developments in elastomer machining over the last two decades and discusses the pros and cons of the same.
{"title":"Cryogenic machining of elastomers: a review","authors":"Preeti Maurya, V. G. S., R. C., B. Shivamurthy","doi":"10.1080/10910344.2021.1903923","DOIUrl":"https://doi.org/10.1080/10910344.2021.1903923","url":null,"abstract":"Abstract Elastomers have visco-elastic behavior and are widely used in general utility as well as sophisticated applications. Generally, elastomer components are produced by molding process. But it is not economical for complicated geometrical elastomeric components of small batch size. Hence, machining is an alternative method of the molding. However, high elasticity, low Young’s modulus and low thermal conductivity in addition to the difficulty of holding elastomer component hinder its machining. To address these challenges, in last two decades, cryogenic assisted milling/turning, cryogenic abrasive jet micromachining (CAJM), ultra-high-pressure water jet machining and low-power CO2 laser cutting were reported and noticed that both machining parameters and cryogenic condition affect the quality of the end-product. The structure-property changes on the surface of elastomer due to cryogenic condition helps in improvement of cutting force, erosion rate, chip formation, surface morphology, and reduction in the abrasive particle embedding at the machined surface. In addition to this, cryogenic assisted machining is a safe environmental alternative approach and it reduces the possibility of abrasive contamination at the machined surface. Hence, this article makes a comprehensive review of developments in elastomer machining over the last two decades and discusses the pros and cons of the same.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"477 - 525"},"PeriodicalIF":2.7,"publicationDate":"2021-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1080/10910344.2021.1903923","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46125462","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-04-13DOI: 10.1080/10910344.2021.1903920
M. K, Amitava Ghosh
Abstract In the present investigation, water based multi-walled carbon nanotube (MWCNT) dispersed nanofluid was produced and used as a cutting fluid in small quantity cooling lubrication (SQCL) assisted grinding of hardened AISI52100 steel. The work material was ground by an alumina wheel. The SQCL technology utilizes atomized aerosol of liquid grinding fluid. Use of MWCNT nanofluid aerosol in place of soluble oil was found to be substantially beneficial in reduction of specific energy and development of compressive residual stress on ground surface. The steady and lower value of the force ratio (tangential to normal grinding force, Ft/Fn) was suggestive of the superior lubrication and grit sharpness retention ability of the aerosol of MWCNT nanofluid. Higher compressive residual stress on the ground surface under MWCNT nanofluid environment suggests lesser grinding zone temperature, which can be attributed to its superior wettability, lubricity and heat dissipation ability of the MWCNT nanofluid. The consumption rate of grinding fluid in SQCL was varied. It could be reduced to 200 ml/h for MWCNT nanofluid to obtain an almost similar or better effect to that of 500 ml/h for soluble oil. Lesser surface tension of MWCNT nanofluid, compared to its counterpart, seemed to facilitate wetting, thus improving lubrication and heat transfer capability further.
{"title":"On grinding force ratio, specific energy, G-ratio and residual stress in SQCL assisted grinding using aerosol of MWCNT nanofluid","authors":"M. K, Amitava Ghosh","doi":"10.1080/10910344.2021.1903920","DOIUrl":"https://doi.org/10.1080/10910344.2021.1903920","url":null,"abstract":"Abstract In the present investigation, water based multi-walled carbon nanotube (MWCNT) dispersed nanofluid was produced and used as a cutting fluid in small quantity cooling lubrication (SQCL) assisted grinding of hardened AISI52100 steel. The work material was ground by an alumina wheel. The SQCL technology utilizes atomized aerosol of liquid grinding fluid. Use of MWCNT nanofluid aerosol in place of soluble oil was found to be substantially beneficial in reduction of specific energy and development of compressive residual stress on ground surface. The steady and lower value of the force ratio (tangential to normal grinding force, Ft/Fn) was suggestive of the superior lubrication and grit sharpness retention ability of the aerosol of MWCNT nanofluid. Higher compressive residual stress on the ground surface under MWCNT nanofluid environment suggests lesser grinding zone temperature, which can be attributed to its superior wettability, lubricity and heat dissipation ability of the MWCNT nanofluid. The consumption rate of grinding fluid in SQCL was varied. It could be reduced to 200 ml/h for MWCNT nanofluid to obtain an almost similar or better effect to that of 500 ml/h for soluble oil. Lesser surface tension of MWCNT nanofluid, compared to its counterpart, seemed to facilitate wetting, thus improving lubrication and heat transfer capability further.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"585 - 607"},"PeriodicalIF":2.7,"publicationDate":"2021-04-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1080/10910344.2021.1903920","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47247285","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-04-01DOI: 10.1080/10910344.2021.1903924
S. Yang, O. Dillon, D. Puleo, I. S. Jawahir
Abstract This study was to determine to what extent a cryogenic surface treatment technique could improve the wear resistance of a Co-Cr-Mo hip implant material. Dry and cryogenic treatments were used to create different surface and sub-surface conditions. The Co-Cr-Mo samples were wear-tested using a pin-on-disk tester in a simulated implant environment. A change in the wear response was found as a function of the material surface properties. Correlation between the treatment conditions and wear volume loss was discussed. Sample from cryogenic treatment was found to be most promising with lower wear volume due to microstructure refinement, compressive residual stresses and preferred hcp phase; moreover, the preferred hcp phase revealed to be the most influencing property in enhancing the wear resistance.
{"title":"Enhancement of wear resistance for improved functional performance of Co-Cr-Mo hip implants through cryogenic surface treatment: a case study","authors":"S. Yang, O. Dillon, D. Puleo, I. S. Jawahir","doi":"10.1080/10910344.2021.1903924","DOIUrl":"https://doi.org/10.1080/10910344.2021.1903924","url":null,"abstract":"Abstract This study was to determine to what extent a cryogenic surface treatment technique could improve the wear resistance of a Co-Cr-Mo hip implant material. Dry and cryogenic treatments were used to create different surface and sub-surface conditions. The Co-Cr-Mo samples were wear-tested using a pin-on-disk tester in a simulated implant environment. A change in the wear response was found as a function of the material surface properties. Correlation between the treatment conditions and wear volume loss was discussed. Sample from cryogenic treatment was found to be most promising with lower wear volume due to microstructure refinement, compressive residual stresses and preferred hcp phase; moreover, the preferred hcp phase revealed to be the most influencing property in enhancing the wear resistance.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"455 - 476"},"PeriodicalIF":2.7,"publicationDate":"2021-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1080/10910344.2021.1903924","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42206327","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-03-04DOI: 10.1080/10910344.2020.1855650
Chandrani Sadhukhan, S. Mitra, R. Biswas, M. K. Naskar
Abstract This article presents flank wear estimation during the turning process of Inconel 718 in dry cutting condition using unscented Kalman filter (UKF). A discrete flank wear model is developed where two components of flank wear due to abrasion and diffusion are considered as state variables and the cutting force is taken as the output variable. The proposed model can be implemented for online tool wear monitoring and the UKF predicts the actual states of tool flank wear in real-time by measuring the cutting force variation. The simulation result of flank wear estimation using UKF is compared with the extended Kalman filter (EKF) under a similar cutting environment. The error of estimation for UKF is obtained less than that of EKF indicating better accuracy of UKF than EKF for tool condition monitoring of the proposed model. Hardware experiments are performed to validate simulated results of both UKF and EKF on the proposed model correlating the cutting force and flank wear components.
{"title":"Tool condition monitoring: unscented Kalman filter for tool flank wear estimation in turning of Inconel 718","authors":"Chandrani Sadhukhan, S. Mitra, R. Biswas, M. K. Naskar","doi":"10.1080/10910344.2020.1855650","DOIUrl":"https://doi.org/10.1080/10910344.2020.1855650","url":null,"abstract":"Abstract This article presents flank wear estimation during the turning process of Inconel 718 in dry cutting condition using unscented Kalman filter (UKF). A discrete flank wear model is developed where two components of flank wear due to abrasion and diffusion are considered as state variables and the cutting force is taken as the output variable. The proposed model can be implemented for online tool wear monitoring and the UKF predicts the actual states of tool flank wear in real-time by measuring the cutting force variation. The simulation result of flank wear estimation using UKF is compared with the extended Kalman filter (EKF) under a similar cutting environment. The error of estimation for UKF is obtained less than that of EKF indicating better accuracy of UKF than EKF for tool condition monitoring of the proposed model. Hardware experiments are performed to validate simulated results of both UKF and EKF on the proposed model correlating the cutting force and flank wear components.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"331 - 348"},"PeriodicalIF":2.7,"publicationDate":"2021-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1080/10910344.2020.1855650","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43820492","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-16DOI: 10.1080/10910344.2020.1855648
N. Anand Krishnan, K. Vipindas, J. Mathew
Abstract An accurate prediction of cutting force is significant, as it plays a critical role on surface quality and tool wear. In micro-endmilling, the machined feature size and feed/tooth are comparable to the material grain size and the edge radius of the endmill. Hence, the effects of scaling issues, material micro-structure and cutting temperature on the machining performance need to be addressed. This article presents a force model for micro-endmilling by incorporating size effect, machining temperature, workpiece spring back effect and micro-structure evolution. The developed force model was validated with experimental results on Inconel 718 and the prediction error was found to be less than 10%. An experimental study to understand the influence of size effect on cutting force, micro-hardness and surface defect during micro-endmilling on Inconel 718 was carried out. Minimum uncut chip thickness was observed adjacent to 0.9 µm. For a feed/tooth less than 0.9 µm, both cutting force and micro-hardness of the endmilled surface shows a nonlinear trend. Higher value of cutting force at feed/tooth less than 0.9 µm was observed due to high strain hardening, and significant plowing effect on the micro-endmilled surfaces.
{"title":"Micro-structure evolution-based force model and surface characteristic studies of Inconel 718 during micro-endmilling","authors":"N. Anand Krishnan, K. Vipindas, J. Mathew","doi":"10.1080/10910344.2020.1855648","DOIUrl":"https://doi.org/10.1080/10910344.2020.1855648","url":null,"abstract":"Abstract An accurate prediction of cutting force is significant, as it plays a critical role on surface quality and tool wear. In micro-endmilling, the machined feature size and feed/tooth are comparable to the material grain size and the edge radius of the endmill. Hence, the effects of scaling issues, material micro-structure and cutting temperature on the machining performance need to be addressed. This article presents a force model for micro-endmilling by incorporating size effect, machining temperature, workpiece spring back effect and micro-structure evolution. The developed force model was validated with experimental results on Inconel 718 and the prediction error was found to be less than 10%. An experimental study to understand the influence of size effect on cutting force, micro-hardness and surface defect during micro-endmilling on Inconel 718 was carried out. Minimum uncut chip thickness was observed adjacent to 0.9 µm. For a feed/tooth less than 0.9 µm, both cutting force and micro-hardness of the endmilled surface shows a nonlinear trend. Higher value of cutting force at feed/tooth less than 0.9 µm was observed due to high strain hardening, and significant plowing effect on the micro-endmilled surfaces.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"875 - 898"},"PeriodicalIF":2.7,"publicationDate":"2021-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1080/10910344.2020.1855648","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47418388","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-15DOI: 10.1080/10910344.2020.1855651
Guohe Li, Meng Liu, Shanshan Zhao
Abstract The finite element method is an important supplement to the experiment on the research of metal cutting mechanism. A 3D thermo-mechanical coupling model was established based on ABAQUS, in which a model of the tool with real structure and a simplified model of the work-piece based on the cutting zone were established. It can greatly improve the computational efficiency because the volume of the work-piece model can be reduced by 70% when compared with the traditional rectangle model. The validation shows that the prediction error of the cutting force is less than 15%, and the prediction results of the chip morphology are in good agreement with the experiment results. In order to reveal the mechanism of high speed milling of 6061-T6 Aluminum alloy, single factor experiments were carried out based on the established model. The results show that the cutting force and cutting temperature rapidly increase with the increase of the axial depth of cut ap and the feed per tooth fz , but slowly increase with the increase of the radial depth of cut ae . The cutting force decreases with the increase of the spindle speed n. However, the cutting temperature increases with the increase of n firstly, and tends to be stable when n is over than 10,000 r/min. GRAPHICAL ABSTRACT
{"title":"Reduced computational time in 3D finite element simulation of high speed milling of 6061-T6 aluminum alloy","authors":"Guohe Li, Meng Liu, Shanshan Zhao","doi":"10.1080/10910344.2020.1855651","DOIUrl":"https://doi.org/10.1080/10910344.2020.1855651","url":null,"abstract":"Abstract The finite element method is an important supplement to the experiment on the research of metal cutting mechanism. A 3D thermo-mechanical coupling model was established based on ABAQUS, in which a model of the tool with real structure and a simplified model of the work-piece based on the cutting zone were established. It can greatly improve the computational efficiency because the volume of the work-piece model can be reduced by 70% when compared with the traditional rectangle model. The validation shows that the prediction error of the cutting force is less than 15%, and the prediction results of the chip morphology are in good agreement with the experiment results. In order to reveal the mechanism of high speed milling of 6061-T6 Aluminum alloy, single factor experiments were carried out based on the established model. The results show that the cutting force and cutting temperature rapidly increase with the increase of the axial depth of cut ap and the feed per tooth fz , but slowly increase with the increase of the radial depth of cut ae . The cutting force decreases with the increase of the spindle speed n. However, the cutting temperature increases with the increase of n firstly, and tends to be stable when n is over than 10,000 r/min. GRAPHICAL ABSTRACT","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"558 - 584"},"PeriodicalIF":2.7,"publicationDate":"2021-01-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://sci-hub-pdf.com/10.1080/10910344.2020.1855651","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45380252","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
京公网安备 11010802042870号
京ICP备2023020795号-1
扫码关注我们
求助内容：
应助结果提醒方式：