A mechanics-based predictive model for chip breaking in metal machining and its validation

Buchkremer, S.; Schoop, Julius

doi:10.1016/j.cirp.2016.04.089

Cited by 11 publications

(3 citation statements)

References 21 publications

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“…Chip formation is directly related to surface quality, tool wear and machining efficiency [5,6]. Thus, the control of the chip formation mechanism at both micro and macro levels is a possible means to improve machinability [7].…”

Section: Introductionmentioning

confidence: 99%

Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V

Abdelnasser,

El-Sanabary,

Nassef

et al. 2023

Micromachines

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This article presents the results of an experimental investigation into the effect of process parameters in the precision hard turning of Ti-6Al-4V on chip morphology at both macro and micro levels. It also reports on the control of chip generation to improve chip evacuation and breakability at the macro level by varying the process parameters, namely, feed rate, cutting speed and depth of cut during turning tests. A scanning electron microscope (SEM) was used to examine the chips produced for a better understanding of chip curling mechanisms at the micro level. Surface roughness of the machined specimens was measured to assess the effect of chip evacuation on obtainable surface quality. From the results, it was found that the interaction of process parameters has a significant effect on the control of chip formation. In particular, the interaction of higher cutting speeds and greater depths of cut produced chip entanglement with the workpiece for all values of feed rates. Using relatively higher feed rates with a low depth of cut showed good results for chip breaking when machining at higher cutting speeds. Different chip curling mechanisms were identified from the SEM results. Chip side-curl formation showed different segmentation patterns with an approximately uniform chip thickness along the chip width, while chip up-curl occurred due to variations in chip thickness. Finally, it was found that the tangling of the chip with the workpiece has a significant effect on the final surface quality.

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Section: Introductionmentioning

confidence: 99%

Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V

Abdelnasser,

El-Sanabary,

Nassef

et al. 2023

Micromachines

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“…Whereas there has been extensive research into establishing the parameters of the material model, the friction model and the fracture model of the work material (see e.g. [5], [6], [7], [8] and many others), little attention has been given to determining the thermal properties of the material for modeling the cutting process. Yet, the thermal properties of the material to be machined have a significant impact on the cutting process characteristics and, particularly on the value of the cutting temperature.…”

Section: Introductionmentioning

confidence: 99%

Determination of thermal material properties for the numerical simulation of cutting processes

Storchak

Stehle

Möhring

2021

Int J Adv Manuf Technol

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Thermal properties of work materials, which depend significantly on the change in cutting temperature, have a considerable effect on thermal machining characteristics. Therefore, the thermal properties used for the numerical simulation of the cutting process should be determined depending on the cutting temperature. To determine the thermal properties of the work materials, a methodology and a software-implemented algorithm were developed for their calculation. This methodology is based on analytical models for the determination of tangential stress in the primary cutting zone. Based on this stress and experimentally or analytically determined cutting temperatures, thermal properties of the work material were calculated, namely the coefficient of the heat capacity as well as the coefficient of thermal conductivity. Three variants were provided for determining the tangential stress: based on the normal stress calculated using the Johnson-Cook constitutive equation, based on the experimentally determined cutting and thrust forces as well as by directly calculating the tangential stress. The thermal properties were determined using the example of three different materials: AISI 1045 and AISI 4140 steel as well as Ti10V2Fe3Al titanium alloy (Ti-1023). With the developed FE cutting model, the deviation between experimental and simulated temperature values ranged from approx. 7.5% to 14.4%.

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“…While machining brittle material the absorption of crack capacity is less so the propagation of crack is easy and form discontinuous chip. In case of ductile material the crack absorption capacity is higher than the brittle material so the crack cannot propagate through chip so it form continuous chip [1][2][3]. Positive higher rake angle improve machinability by reducing the friction between sliding chip and tool [2] Since effective chip control is necessary for automatic production system because any failure in chip control can cause lowering the productivity and worsening the operation due to frequent stop due to removal of chip from chuck and tool and to reduce the hazards to the operator [1].…”

Section: Introductionmentioning

confidence: 99%

Effect of Rake Angle on Chip Control in CNC Lathe Machining of Low Carbon Steel

Uthaykumar¹,

Prasanna²,

Simson³

et al. 2016

BIJIEMS

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This paper aims to ingenuity of the machining of low carbon steel in order to control chip length and reduce cycle time of the component, to improve surface finish by increasing Rake angle. This approach is used to reduce hazard to the operator. Surface roughness is measured by digital dial gauge. Heat generated during the turning operation is measured by using thermocouple. It gives clear perception about the rake angle. Parameter levels are adjusted according to insert grade to handbook and discussed about the efficient coolant flow condition. This paper reviews various machining parameters which affect turning operation of low carbon steel. Such as insert geometry, coolant flow, heat dissipation, depth of cut, spindle speed, feed rate.

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A mechanics-based predictive model for chip breaking in metal machining and its validation

Cited by 11 publications

References 21 publications

Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V

Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V

Determination of thermal material properties for the numerical simulation of cutting processes

Effect of Rake Angle on Chip Control in CNC Lathe Machining of Low Carbon Steel

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