An Evaluation of Ploughing Models for Orthogonal Machining

Waldorf, Daniel; DeVor, Richard E.; Kapoor, Shiv Gopal

doi:10.1115/1.2833050

Cited by 71 publications

(63 citation statements)

References 31 publications

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“…Experimental and analytical studies discussed in [9] to [11] concluded that a dead metal zone is mostly dependent on the geometry of the chamfered part rather than the cutting conditions. Meanwhile, the dead zone is also formed with the blunt tool in the same way as for the chamfered tool, which is in good agreement with the results of assumption of the formation of BUE discussed by Waldorf et al [12] for large-radius tools. The region of the missing zone determines the region of the dead zone.…”

Section: Investigations On the Effects Of Different Tool Edge Geometrsupporting

confidence: 80%

Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining

Wan¹,

Wang²,

Gao³

2015

SV-JME

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Section: Investigations On the Effects Of Different Tool Edge Geometrsupporting

confidence: 80%

Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining

Wan¹,

Wang²,

Gao³

2015

SV-JME

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“…One of the issues faced by Wu and Endres was that in assuming that the tool has a rounded edge (as may be the case in practice), there is no longer a finite tool tip that can be used to define the depth of cut and the flank penetration. Waldorf et al [23] investigated this issue by comparing theoretical predictions from two ploughing models with experimental behaviour. They found that it is more appropriate to model the rounded tool tip with a stable built-up edge attached, so that the tool can be thought of as having a chamfer.…”

Section: Literature Reviewmentioning

confidence: 99%

The influence of feed rate on process damping in milling: modelling and experiments

Sims

Turner

2011

Proceedings of the Institution of Mechanical Engineers, Part B:

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eprints@whiterose.ac.uk https://eprints.whiterose.ac.uk/ Reuse Unless indicated otherwise, fulltext items are protected by copyright with all rights reserved. The copyright exception in section 29 of the Copyright, Designs and Patents Act 1988 allows the making of a single copy solely for the purpose of non-commercial research or private study within the limits of fair dealing. The publisher or other rights-holder may allow further reproduction and re-use of this version -refer to the White Rose Research Online record for this item. Where records identify the publisher as the copyright holder, users can verify any specific terms of use on the publisher's website. TakedownIf you consider content in White Rose Research Online to be in breach of UK law, please notify us by emailing eprints@whiterose.ac.uk including the URL of the record and the reason for the withdrawal request. DOI: 10.1243/09544054JEM2141Abstract: The performance of milling operations is limited by the onset of unstable self-excited vibrations known as regenerative chatter. Over the past few decades there has been a great deal of research to help predict and explain regenerative chatter. Consequently, high-speed milling operations are now frequently employed, with judicious choice of spindle speeds and depths of cut so as to avoid chatter whilst maintaining high productivity. However, many materials that are increasingly used in aerospace components are difficult to machine at high spindle speeds because of their thermal properties. Examples include titanium and nickel alloys. For these materials, low-speed machining must be employed, and in this regime the role of regenerative chatter is less clearly understood due to the phenomenon of process damping. In the present study, a time domain model of process damping is developed. This model is used to explore the relationship between cutting conditions and the amplitude of chatter vibrations. A qualitative agreement is found between experimental behaviour and the numerical model. In particular, the model predicts a strong relationship between the workpiece feed rate (expressed as a feed per tooth), and the acceptable chatter stability defined by the process damping wavelength. Further work is needed to properly calibrate some of the model parameters.

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“…In recent years, many slip-line field models have been specifically developed for the microscale [9][10][21][22][23][24][25][26][27][28][29] and all of them consider a rounded tool edge.…”

Section: State Of the Artmentioning

confidence: 99%

“…-a stable built-up edge, named "dead metal cap", is claimed by some researchers to be always present when machining with an uncut chip thickness lower than the tool cutting edge radius [9][10][11].…”

Section: Introductionmentioning

confidence: 99%

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Applicability of an orthogonal cutting slip-line field model for the microscale

Rebaioli

Biella

Annoni

et al. 2014

Proceedings of the Institution of Mechanical Engineers, Part B:

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Mechanical micromachining is a very flexible and widely exploited process, but its knowledge should still be improved since several incompletely explained phenomena play a role on the microscale chip removal (e.g. "minimum chip thickness effect", microstructure influence on cutting forces, stable built-up edge, etc.). Several models have been developed to describe the machining process, but only some of them take into account a rounded-edge tool, which is a typical condition in micromachining. Among these models, the slip-line field model developed by Waldorf for the macroscale allows to separately evaluate shearing and ploughing force components in orthogonal cutting conditions, therefore it is suitable to predict cutting forces when a large ploughing action occurs, as in micromachining. The present study aims at demonstrating how this model is suitable also for micromachining conditions. In order to achieve this goal, a clear, modular and repeatable procedure has been developed for objectively validating its cutting and feed force prediction performance at low uncut chip thickness (less than 50 µm) and relatively higher cutting edge radius. The proposed procedure makes the model generally applicable after a suitable and 2 non-extensive calibration campaign. The present paper shows how calibration experiments can be selected among the available database of cutting trials basing on the model force prediction capability. Final validation experiments have been used to show how the model is robust to a cutting speed variation even if the cutting speed is not among the model quantities. A suitable set-up, especially designed for microturning conditions, has been used in this research to measure forces and chip thickness. Tests have been carried out on 6082-T6 Aluminum alloy with different cutting speeds and different ratios between uncut chip thickness and cutting edge radius.

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An Evaluation of Ploughing Models for Orthogonal Machining

Cited by 71 publications

References 31 publications

Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining

Investigations on the Effects of Different Tool Edge Geometries in the Finite Element Simulation of Machining

The influence of feed rate on process damping in milling: modelling and experiments

Applicability of an orthogonal cutting slip-line field model for the microscale

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