Automated Evaluation of Continuous and Segmented Chip Geometries Based on Image Processing Methods and a Convolutional Neural Network

Klippel, Hagen; Pflaum, Samuel; Kuffa, Michal; Wegener, Konrad

doi:10.36897/jme/156091

Cited by 3 publications

(1 citation statement)

References 20 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…For the evaluation of the chip cross-sections, the automated analysis methodology from [17] is applied. The methodology uses image processing techniques to extract various chip parameters, where for this work, only the chip thickness is taken into account.…”

Section: Data Evaluationmentioning

confidence: 99%

Enhancing Orthogonal Finishing Machining of Ti6Al4V with Laser Modified Tools

Kneubühler,

Zhang,

Haudenschild

et al. 2024

Preprint

View full text Add to dashboard Cite

Finishing machining of Ti6Al4V, known for its high strength and heat conduction resistance, demands optimisation to achieve high-quality end products. This study explores modifying the chip contact length on the rake face and altering the flank face with a cavity to minimise process forces and temperatures, while maintaining cutting edge integrity. The research validates the manufacturability of laser-modified tools through ultra-short pulsed laser ablation, indicating potential for industrial scale-up. Extensive experimental evaluations under dry conditions assess the impact of tool modifications at various feed rates for planing and turning. Significant reductions in process forces and temperatures were observed with rake face modifications, particularly at a cavity distance of approximately \qty{34}{\micro\meter}. Ideal performance was noted for feed rates between \qtyrange[range-units=single]{0.035}{0.045}{\milli\meter} for planing and \qtyrange[range-units=single]{0.040}{0.045}{\milli\meter}/rev for turning. Smoothed Particle Hydrodynamics (SPH) simulations employing a Johnson-Cook material model were used to analyse chip formation and to predict the process forces. These simulations revealed a clear change in the chip formation and lower process forces and temperatures. The SPH results closely matched experimental outcomes, with a discrepancy of less than \qty{7}{\percent} in cutting forces for both tool types, although feed forces were underestimated by about \qty{50}{\percent}. The effect o the tool modification is reflected accurately at the specified feeds.

show abstract

Section: Data Evaluationmentioning

confidence: 99%

Enhancing Orthogonal Finishing Machining of Ti6Al4V with Laser Modified Tools

Kneubühler,

Zhang,

Haudenschild

et al. 2024

Preprint

View full text Add to dashboard Cite

show abstract

Enhancing orthogonal finishing machining of Ti6Al4V with laser-ablated tool geometry modifications

Kneubühler,

Zhang,

Haudenschild

et al. 2024

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Finishing machining of Ti6Al4V, known for its high strength and heat conduction resistance, demands optimisation to achieve high-quality end products. This study explores modifying the chip contact length on the rake face and altering the flank face with a cavity to minimise process forces and temperatures while maintaining cutting edge integrity. The research validates the manufacturability of ultra-short pulsed laser-ablated tool geometry modifications, indicating potential for industrial scale-up. Extensive experimental evaluations under dry conditions assess the impact of tool modifications at various feed rates for planing and turning. Significant reductions in process forces and temperatures were observed with rake face modifications, particularly at a cavity distance of approximately 34 µm. Ideal performance was noted for feed rates between 0.035 and 0.045 mm for planing and 0.040 to 0.045 mm/rev for turning. Smoothed Particle Hydrodynamics (SPH) simulations employing a Johnson-Cook material model were used to analyse chip formation and to predict the process forces. These simulations revealed a clear change in the chip formation and lower process forces and temperatures. The SPH results closely matched experimental outcomes, with a discrepancy of less than 7 % in cutting forces for both tool types, although feed forces were underestimated by about 50 %. The effect of the tool modification is reflected accurately at the respective feeds.

show abstract

An Attempt for Numerical Optimisation of a Micro-Groove Geometry at The Rake Face When Turning Ti6Al4V Alloy with Indexable Inserts

Klippel,

Kneubühler,

Haudenschild

et al. 2024

Journal of Machine Engineering

View full text Add to dashboard Cite

Machining of Ti6Al4V is considered difficult because the material removal rates are relatively small if the tool wear shall be low. In recent years the reduction of process forces as well as tool wear have been investigated by introducing textures (pockets) into the tool surface. To advance the understanding how those textured tools function and to reduce the experimental effort, a smoothed particle hydrodynamics (SPH) model of the orthogonal cutting process with a parametrised tool containing a single pocket on the rake face with variable position and depth is presented. This simulation model is used to enhance the understanding of rake face textures in order to design optimum cutting tools for given process parameters. Using an optimisation algorithm, an optimum texture geometry is determined numerically and is then experimentally validated, followed by a discussion, why process force reductions are lower than predicted.

show abstract

Automated Evaluation of Continuous and Segmented Chip Geometries Based on Image Processing Methods and a Convolutional Neural Network

Cited by 3 publications

References 20 publications

Enhancing Orthogonal Finishing Machining of Ti6Al4V with Laser Modified Tools

Enhancing Orthogonal Finishing Machining of Ti6Al4V with Laser Modified Tools

Enhancing orthogonal finishing machining of Ti6Al4V with laser-ablated tool geometry modifications

An Attempt for Numerical Optimisation of a Micro-Groove Geometry at The Rake Face When Turning Ti6Al4V Alloy with Indexable Inserts

Contact Info

Product

Resources

About