A Method to Determine the Minimum Chip Thickness during Longitudinal Turning

Skrzyniarz, Michał

doi:10.3390/mi11121029

Cited by 15 publications

(11 citation statements)

References 20 publications

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“…The material was steel 1.2709. As the condition of the cutting edge and its sharpness are some of the key factors in cutting operations [29,30], the analysis of the additively manufactured tool focused on determining its dimensional and geometric accuracy, the cutting edge radius and the surface quality.…”

Section: Introductionmentioning

confidence: 99%

Geometry, Structure and Surface Quality of a Maraging Steel Milling Cutter Printed by Direct Metal Laser Melting

2022

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This article considers the use of additive manufacturing to produce cutting tools for various machining operations, especially turning, milling, and drilling. The right geometry and material of the tool as well as coatings applied on cutting edges are crucial as they improve the life and performance of the tool. The study described here focused on a four-flute end mill made of maraging steel 1.2709 using a Concept Laser M2 Cusing Direct Metal Laser Melting (DMLM) machine. Before the printed tool was first used, it was examined to determine its dimensional and geometric accuracy, surface roughness, and surface structure. The measurement data showed that the tool required machining, e.g., grinding, to improve its geometry because the total runout of the shank and the cutting edge radius were too high, amounting to 120 μm and 217 μm, respectively. The cutting edges were sharpened to obtain a fully functional cutting tool ready to perform milling operations. The study aimed to check the dimensional and geometric accuracy of the 3D printed milling cutter and determine the optimal machining allowance for its finishing.

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Section: Introductionmentioning

confidence: 99%

Geometry, Structure and Surface Quality of a Maraging Steel Milling Cutter Printed by Direct Metal Laser Melting

2022

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“…In the lists created by the authors of previous works, the factors influencing shaped surfaces have been selected and divided into main groups related to [ 7 , 8 ] cutting tool, machining parameters, properties of the machined material, and phenomena accompanying the machining [ 9 , 10 ]. Phenomena involved in machining that affect the surface quality are: machining forces, chip forming and detachment, friction in the machining zone, vibration acceleration, displacement, built-up edge, and temperature distribution and flow [ 11 ]. In many works, models for predicting the roughness values of Ra and Rt are often found, as these are the most common industry requirements for roughness for manufactured parts.…”

Section: Introductionmentioning

confidence: 99%

Influence of Relative Displacement on Surface Roughness in Longitudinal Turning of X37CrMoV5-1 Steel

et al. 2021

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The shaping process of surface texture is complicated and depends on many factors and phenomena accompanying them. This article presents the author’s test stand for the measurement of relative displacements in a tool–workpiece system during longitudinal turning. The aim of this study was to determine the influence of edge radius on the relative displacement between the tool and workpiece. The cutting process was carried out with inserts with different edge radii for X37CrMoV5-1 steel. As a result of the research, vibration charts of the tool–workpiece system were obtained. In the range of feed 0.03–0.18 mm/rev, the values of the standard deviation of relative displacements in the x-axis were obtained in the range of 0.36–0.78 μm for the insert with an edge radius of rn = 48.8 μm. As a result of the work, it was determined that for the feed value of 0.12 mm/rev for all inserts, the relative displacements are the smallest. As the final effect, the formula for forecasting the Ra roughness parameter was presented.

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“…Dib et al [17] determined the minimum uncut chip thickness by means of cutting forces from the dynamometer. Skrzyniarz et al [18] determined the minimum uncut chip thickness of micro turning from a surface profile 2 of 15 obtained with a contact profilometer. Vogler et al [19] found the minimum uncut chip thickness values in micro-milling ferrite and pearlite materials through finite element simulations.…”

Section: Introductionmentioning

confidence: 99%

Prediction of Nonlinear Micro-Milling Force with a Novel Minimum Uncut Chip Thickness Model

et al. 2021

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The minimum uncut chip thickness (MUCT), dividing the cutting zone into the shear region and the ploughing region, has a strong nonlinear effect on the cutting force of micro-milling. Determining the MUCT value is fundamental in order to predict the micro-milling force. In this study, based on the assumption that the normal shear force and the normal ploughing force are equivalent at the MUCT point, a novel analytical MUCT model considering the comprehensive effect of shear stress, friction angle, ploughing coefficient and cutting-edge radius is constructed to determine the MUCT. Nonlinear piecewise cutting force coefficient functions with the novel MUCT as the break point are constructed to represent the distribution of the shear/ploughing force under the effect of the minimum uncut chip thickness. By integrating the cutting force coefficient function, the nonlinear micro-milling force is predicted. Theoretical analysis shows that the nonlinear cutting force coefficient function embedded with the novel MUCT is absolutely integrable, making the micro-milling force model more stable and accurate than the conventional models. Moreover, by considering different factors in the MUCT model, the proposed micro-milling force model is more flexible than the traditional models. Micro-milling experiments under different cutting conditions have verified the efficiency and improvement of the proposed micro-milling force model.

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A Method to Determine the Minimum Chip Thickness during Longitudinal Turning

Cited by 15 publications

References 20 publications

Geometry, Structure and Surface Quality of a Maraging Steel Milling Cutter Printed by Direct Metal Laser Melting

Geometry, Structure and Surface Quality of a Maraging Steel Milling Cutter Printed by Direct Metal Laser Melting

Influence of Relative Displacement on Surface Roughness in Longitudinal Turning of X37CrMoV5-1 Steel

Prediction of Nonlinear Micro-Milling Force with a Novel Minimum Uncut Chip Thickness Model

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