Advanced Tool Edge Geometry for High Precision Hard Turning

Klocke, Fritz; Kratz, Henrik

doi:10.1016/s0007-8506(07)60046-8

Cited by 90 publications

(36 citation statements)

References 8 publications

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“…Chamfered and waterfall type microgeometry inserts can also have variable edge preparation. As for variable chamfered edge design, the goal will be to calculate optimum chamfer angle and chamfer height for given uncut chip thickness along the cutting edge as detailed in Klocke and Kratz (2005). The purpose of continuously changing the chamfer angle along the corner radius is to alter the locations of high temperature zones and reduce the possibility of a crater wear formation.…”

Section: Advanced Cutting Tool Microgeometry Designmentioning

confidence: 99%

Process simulations for 3D turning using uniform and variable microgeometry PCBN tools

Özel

2008

IJMMM

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Abstract:In this paper, uniform and variable edge microgeometry design inserts are utilised and tested for 3D turning process. In 3D tool engagement with workpiece, thickness of the chip varies from a maximum equal to the feed rate (at primary cutting edge) to a minimum on the tool's corner radius (at trailing cutting edge). The ideal tool edge preparation should posses a variable configuration which has larger edge radius at the primary cutting edge than at the trailing cutting edge. Here the key parameter is the ratio of uncut chip thickness to edge radius. If a proper ratio is chosen for given cutting conditions, a variable cutting edge along the corner radius can be designed or 'engineered'. In this study, Finite Element Modelling (FEM)-based 3D process simulations are utilised to predict forces and temperatures on various uniform and variable edge microgeometry tools. Predicted forces are compared with experiments. The temperature distributions on the tool demonstrate the advantages of variable edge microgeometry design.

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Section: Advanced Cutting Tool Microgeometry Designmentioning

confidence: 99%

Process simulations for 3D turning using uniform and variable microgeometry PCBN tools

Özel

2008

IJMMM

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“…The shape of the tool edge becomes one of the major factors in influencing the cutting process [52,54,76,77]. In nano-cutting process, it is important to study machining this type of materials, such as hard and brittle materials by using a diamond tool with special chamfer in the tool edge [78].…”

Section: Influence On Cutting Forcementioning

confidence: 99%

Recent Advances in Micro/Nano-cutting: Effect of Tool Edge and Material Properties

Fang

2018

Nanomanuf Metrol

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Micro-and nano-machining technology has been applied in industry to generate high-precision parts with micro/nanometric accuracy or feature size in the recent decades. Cutting is one of the most powerful manufacturing processes, and the material removal mechanism is urgently demanded by the industry to understand and improve the micro/nano-machining process efficiently at a low cost. This paper presents the recent advances in cutting mechanism and its applicability for predicting the surface generation and chip formation, especially when material is removed in micro-and nanoscale. In addition to the industry-concerned performance parameters, fundamental physical parameters such as stresses, strains, temperatures, phase transformation, minimum uncut chip thickness and size effects are discussed in this paper for the indepth understanding of the micro/nano-cutting process.

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“…The finite-element method can provide a comprehensive and in some cases complementary approach to experimental, mechanistic or analytical approaches to study machining process [19,[23][24][25]. It offers capability to predict what could happen during the material removal process, and thus it could be possible to design and modify the process input parameters beforehand in order to reduce or eliminate problems that may arise during actual machining operations.…”

Section: Finite-element Modelingmentioning

confidence: 99%

Finite-element Modeling and Simulation

Arrazola

2011

Machining of Hard Materials

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This chapter deals with the finite-element method (FEM) of hard machining, mainly turning (two-and three-dimensional (3D)). Results about the influence of working conditions and tool geometry (cutting-edge finishing) on tool forces, temperatures, and stresses when machining AISI 52100 steel are presented. In addition, information about residual stresses obtained through 3D FEM analysis is shown. The aim of the chapter is to demonstrate the possibilities of FEM for understanding the chip formation process in hard turning and to show its capabilities in areas like tool insert design and prediction of the surface state of the machined workpiece. First, a brief summary of the state of the art on hard machining is presented. Then FEM capabilities and limitations are shown. After that, results of process simulations will be provided and compared with those obtained in the literature. Finally, overall conclusions are pointed out and future research direction is discussed. IntroductionHard turning has become a relevant manufacturing process in producing finished components that are made of alloyed steels with hardnesses between 50 and 70 HRC [1]. The main aim of employing hard turning is avoiding the grinding operation which in most cases corresponds to the final operation for the workpiece. Comparisons between both processes show that the demanded surface roughness and ISO tolerance standards can be achieved in both processes, but higher flexibility and material removal rates can be obtained in hard turning.

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Advanced Tool Edge Geometry for High Precision Hard Turning

Cited by 90 publications

References 8 publications

Process simulations for 3D turning using uniform and variable microgeometry PCBN tools

Process simulations for 3D turning using uniform and variable microgeometry PCBN tools

Recent Advances in Micro/Nano-cutting: Effect of Tool Edge and Material Properties

Finite-element Modeling and Simulation

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