Cutting Forces Assessment in CNC Machining Processes: A Critical Review

Sousa, Vítor F. C.; Silva, Francisco; Fecheira, J.S.; Lopes, H.; Martinho, R. P.; Casais, R. B.; Ferreira, Luı́s Pinto

doi:10.3390/s20164536

Cited by 51 publications

(28 citation statements)

References 101 publications

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“…This is due to the improvement of the mechanical properties of the tool by the coating, such as increased hardness, oxidation resistance, toughness, thermal stability (ability to retain microstructure at higher temperatures) and reduced friction coefficient. The employment of tool coatings also contributes for a better surface quality of the machined part [18] and reduction of the cutting forces developed during the machining process (especially due to reduction in friction coefficient), still a very important aspect in today's research of these cutting processes [19]. However, regarding tool-tip temperature and machining temperature, it has been reported that coated tools usually experience higher machining temperatures than uncoated tools [20].…”

Section: Introductionmentioning

confidence: 99%

Characteristics and Wear Mechanisms of TiAlN-Based Coatings for Machining Applications: A Comprehensive Review

Sousa

Silva

Pinto

et al. 2021

Metals

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The machining process is still a very relevant process in today’s industry, being used to produce high quality parts for multiple industry sectors. The machining processes are heavily researched, with the focus on the improvement of these processes. One of these process improvements was the creation and implementation of tool coatings in various machining operations. These coatings improved overall process productivity and tool-life, with new coatings being developed for various machining applications. TiAlN coatings are still very present in today’s industry, being used due to its incredible wear behavior at high machining speeds, high mechanical properties, having a high-thermal stability and high corrosion resistance even at high machining temperatures. Novel TiAlN-based coatings doped with Ru, Mo and Ta are currently under investigation, as they show tremendous potential in terms of mechanical properties and wear behavior improvement. With the improvement of deposition technology, recent research seems to focus primarily on the study of nanolayered and nanocomposite TiAlN-based coatings, as the thinner layers improve drastically these coating’s beneficial properties for machining applications. In this review, the recent developments of TiAlN-based coatings are going to be presented, analyzed and their mechanical properties and cutting behavior for the turning and milling processes are compared.

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Section: Introductionmentioning

confidence: 99%

Characteristics and Wear Mechanisms of TiAlN-Based Coatings for Machining Applications: A Comprehensive Review

Sousa

Silva

Pinto

et al. 2021

Metals

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“…There are two main methods of determining cutting forces, using a direct or indirect approach; however, the most employed method is a direct one using a dynamometer to measure these forces. There are also developments of new predictive methods or models used for the prediction of these cutting forces, especially using Finite Element Method [ 43 ], providing a cheaper alternative for cutting forces prediction and tool behavior.…”

Section: Introductionmentioning

confidence: 99%

Wear Behavior and Machining Performance of TiAlSiN-Coated Tools Obtained by dc MS and HiPIMS: A Comparative Study

et al. 2021

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Duplex stainless steels are being used on applications that require high corrosion resistance and excellent mechanical properties, such as the naval and oil-gas exploration industry. The components employed in these industries are usually obtained by machining; however, these alloys have low machinability when compared to conventional stainless steels, usually requiring the employment of tool coatings. In the present work, a comparative study of TiAlSiN coating performance obtained by these two techniques in the milling of duplex stainless-steel alloy LDX 2101 was carried out. These coatings were obtained by the conventional direct current magnetron sputtering (dc MS) and the novel high power impulse magnetron sputtering (HiPIMS). The coatings were analyzed and characterized, determining mechanical properties for both coatings, registering slightly higher mechanical properties for the HiPIMS-obtained coating. Machining tests were performed with varying cutting length and feed-rate, while maintaining constant values for axial and radial depth of cut and cutting speed. The surface roughness of the material after machining was assessed, as well as the wear sustained by each of the tool types, identifying the wear mechanisms and behavior of these tools, as well as registering the flank wear values presented for each of the tested tools. The HiPIMS-obtained coating exhibited a very similar behavior when compared to the other, producing similar surface roughness quality. However, the HiPIMS coating exhibited less wear for higher cutting lengths, proving to be a better choice in this case, especially regarding tool life.

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“…The application of genetic programming approach in cutting force prediction in milling found that cutting forces could be conventionally calculated with known empirical cutting parameter [12].…”

Section: Introductionmentioning

confidence: 99%

Prediction of cutting force based on machining parameters on AL7075‐T6 aluminum alloy by response surface methodology in end milling

Sethupathy

Shanmugasundaram

2021

Materialwissenschaft Werkst

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Cutting forces modeling is the basic to understand the cutting process, which should be kept in minimum to reduce tool deflection, vibration, tool wear and optimize the process parameters in order to obtain a high quality product within minimum machining time. In this paper a statistical model has been developed to predict cutting force in terms of geometrical parameters such as rake angle, nose radius of cutting tool and machining parameters such as cutting speed, cutting feed and axial depth of cut. Response surface methodology experimental design was employed for conducting experiments. The work piece material is Aluminum (Al 7075‐T6) and the tool used is high speed steel end mill cutter with different tool geometry. The cutting forces are measured using three axis milling tool dynamometer. The second order mathematical model in terms of machining parameters is developed for predicting cutting forces. The adequacy of the model is checked by employing ANOVA. The direct effect of the process parameter with cutting forces are analyzed, which helps to select process parameter in order to keep cutting forces minimum, which ensures the stability of end milling process. The study observed that feed rate has the highest statistical and physical influence on cutting force.

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Cutting Forces Assessment in CNC Machining Processes: A Critical Review

Cited by 51 publications

References 101 publications

Characteristics and Wear Mechanisms of TiAlN-Based Coatings for Machining Applications: A Comprehensive Review

Characteristics and Wear Mechanisms of TiAlN-Based Coatings for Machining Applications: A Comprehensive Review

Wear Behavior and Machining Performance of TiAlSiN-Coated Tools Obtained by dc MS and HiPIMS: A Comparative Study

Prediction of cutting force based on machining parameters on AL7075‐T6 aluminum alloy by response surface methodology in end milling

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