Chip control in turning with synchronization of spindle rotation and feed motion vibration

Miyake, Akihito; Kitakaze, Ayako; Katoh, Seiko; Muramatsu, Masahiro; Noguchi, Kenji; Sannomiya, Kazuhiko; Nakaya, Takaichi; Sasahara, Hiroyuki

doi:10.1016/j.precisioneng.2018.02.012

Cited by 21 publications

(11 citation statements)

References 14 publications

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“…Equation (8) shows that the length of the chip produced by vibration cutting is smaller than the length of the chip produced by traditional cutting. This phenomenon can also be observed in the experiment of A. Miyake et al, which is beneficial to cutting [23]:…”

Section: Theoretical Study Of Vibration Cuttingsupporting

confidence: 58%

Research on Cooling Technology of Shredder Cutting Tool With Ultrasonic Vibration-Assisted Cutting

Qian

Liu

et al. 2019

IEEE Access

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To improve service life of shredder cutters, new technologies such as ultrasonic vibrationassisted cutting and cooling technology (jet and spray) are introduced into the design of the cutter for a two-axis horizontal shredder. Ultrasonic vibration-assisted cutting technology is theoretical analyzed, and result shows that the effect of friction reduction only happens when the speed of cutting is less than vibration speed. Therefore, the vibration-assisted cutting get a friction reduction of 52.5% and a cutting temperature reduction of 10.5% when the vibration-assisted cutting with an amplitude of 25 µm and a frequency of 20 kHz is performed on the shredder with the rotational speed of 60 r/min. Three cooling methods are proposed to lower the temperature of shredder tools such as air jet cooling, water jet cooling, and spray cooling. They are all simulated with Ansys-fluent software on the basis of the Lagrangian model. Simulation results show that water jet cooling can realize better cooling effect, whereas its cooling effect will not improve obviously until the jet diameter increases to around 4 mm. In addition, the cooling effect of the spray with vibration cutting which has less coolant consumption is very close to that of the water jet without vibration cutting. Therefore, the mode of spray cooling with vibration cutting can be used instead of the mode of water jet cooling for higher coolant utilization. By comparing with the traditional cutting of shredder, the spray cooling with vibration cutting has a cutting temperature reduction of 65%.INDEX TERMS Shredder, vibration cutting, tool temperature, jet cooling, spray cooling.

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Section: Theoretical Study Of Vibration Cuttingsupporting

confidence: 58%

Research on Cooling Technology of Shredder Cutting Tool With Ultrasonic Vibration-Assisted Cutting

Qian

Liu

et al. 2019

IEEE Access

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“…Regarding application of UAD, this leads to the demand of synchronization of ultrasonic vibration frequency and rotation speed. This approach is well known for vibration-assisted machining, especially vibration-assisted turning with low frequencies [41,42,44,50]. In addition, the ratio between feed per tooth and ultrasonic amplitude, respectively, the minimum of the dynamic feed, defines the fundamental process characteristics in terms of intermitted and continuous cutting.…”

Section: Aspects Of Process Designmentioning

confidence: 99%

Kinematic analysis and process stability of ultrasonic-assisted drilling

Georgi

Rüger

Rentzsch

et al. 2021

Int J Adv Manuf Technol

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Regarding drilling, ultrasonic-assistance enables various potentials such as less tool wear, enhanced chip breaking and burr reduction. Although there are many technological studies verifying these advantages, no theory for process behaviour, design and parameter evaluation is available. Thus, this paper presents a kinematic analysis of the interaction between tool and workpiece to contribute to overall process understanding. Specific process scenarios are classified and characteristic parameters for the evaluation and design of ultrasonic-assisted drilling are determined. In addition, experimental investigations based on the developed process model are carried out analysing chip shape, bore surface and process stability acquired by acoustic measurements. The kinematic analysis shows the classification of ultrasonic-assisted drilling according to continuous and intermitted cutting conditions. In addition, the superposition of ultrasonic vibrations causes a modulation of uncut chip thickness related to the ratio of ultrasonic frequency and spindle speed. In general, experimental results show that ultrasonic-assisted drilling is leading to shorter chips. While using parameters for intermitted cutting conditions needle chips occur. At the same time, intermitted cutting conditions induce process instabilities identified using the acoustic measurement approach.

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“…Discontinuous and fragmented chips are easier to control as continuous chips can wrap around the workpiece and/or the cutting tool and clog the cutting zone, which negatively affects the cutting process. Such chips can scratch the newly machined surface, detract from its quality and increase tool wear/breakage thereby decreasing tool life [17,18]. This results in a higher number of production stops and, therefore, in a dramatic increase of production time.…”

Section: Introductionmentioning

confidence: 99%

“…This results in a higher number of production stops and, therefore, in a dramatic increase of production time. Thus, the chip formation process and chip control using combined cryogenic and minimum quantity lubrication [19,20], applying cryogenic lubrication [7,21], high pressure coolant [2,11] ultrasonic-assisted vibration [15,17], optimization of the processing parameters [10,[22][23][24], and chip breakers [10,14,16] as well as their limitations [25], have been widely studied, both experimentally and by means of simulation. It is widely accepted that the contribution of chip breakers in enhancing the chip fragmentation process is significant.…”

Section: Introductionmentioning

confidence: 99%

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

2019

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Chip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This scenario can be avoided by using a properly designed chip breaker. Despite their relevance, chip breakers are not in wide-spread use in polycrystalline diamond (PCD) cutting tools. This paper presents a systematic methodology to design chip breakers for PCD turning inserts through finite element modelling. The goal is to evacuate the formed chips from the cutting zone controllably and thus, maintain surface quality. Particularly, different scenarios of the chip formation process and chip curling/evacuation were simulated for different tool designs. Then, the chip breaker was produced by laser ablation. Finally, experimental validation tests were conducted to confirm the ability of this chip breaker to evacuate the chips effectively. The machining results revealed superior performance of the insert with chip breaker in terms of the ability to produce curly chips and high surface quality (Ra = 0.51–0.56 µm) when compared with the insert without chip breaker that produced continuous chips and higher surface roughness (Ra = 0.74–1.61 µm).

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Chip control in turning with synchronization of spindle rotation and feed motion vibration

Cited by 21 publications

References 14 publications

Research on Cooling Technology of Shredder Cutting Tool With Ultrasonic Vibration-Assisted Cutting

Research on Cooling Technology of Shredder Cutting Tool With Ultrasonic Vibration-Assisted Cutting

Kinematic analysis and process stability of ultrasonic-assisted drilling

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

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