Experimental research on the critical conditions and critical equation of chip splitting when turning a C45E4 disc workpiece symmetrically with a high-speed steel double-edged turning tool

Xu, Mingxian; Xiong, Liangshan; Zhu, Biwu; Zheng, Lina; Yin, Kedong

doi:10.1007/s40436-021-00378-7

Cited by 2 publications

(1 citation statement)

References 29 publications

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“…It was revealed that large inclination angle and negative rake angle lead to higher chip splitting with increased chip thickness. It is to be noted here that chip splitting also lead to reduced specific cutting force and feed force [27]. Apart from parallel turning, numerical and experimental investigation was performed on parallel milling to estimate the residual stress considering initial stresses.…”

Section: Literature Reviewmentioning

confidence: 99%

Numerical Analysis of Surface Integrity in Parallel Turning Process Part II: Influence of Cutting Tool Rake Angle

Kalidasan

2022

KEM

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Parallel turning is one among the advanced unconventional turning process. It employs two turning tools operating concurrently to cut the material from the workpiece. For turned rotary components, surface integrity is a major quality indicator that determines the fatigue life of the finished workpiece. Tool parting distance, rake angle and edge radius affects surface integrity. Part I dealt with numerical analyses to determine the effect of parting distance on surface integrity using finite element based commercial software Abaqus 6.14. Here in Part II, the impact of rake angle over surface integrity for various cutting speeds and feeds are numerically analyzed. It was observed that with the rise in negative rake angle the negative residual stresses decreased for the machined surface of leading and lagging cutting tool. When the rake angle is increased from-10 ̊ to-2 ̊, percentage reduction of negative residual stresses is same for the turned surfaces of both tools. The cutting velocity was 250 m/min and feed 0.2 mm/rev. With the rise in rake angle, the friction angle reduced but shear angle raised. When the cutting velocity increased, the shear angle of the leading and lagging cutting tool reduced. Lower shear angle causes higher stagnation region which further causes higher compressive surface residual stress.

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Section: Literature Reviewmentioning

confidence: 99%

Numerical Analysis of Surface Integrity in Parallel Turning Process Part II: Influence of Cutting Tool Rake Angle

Kalidasan

2022

KEM

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Experimental Modeling of the Bifurcation Set Equation of the Chip-Splitting Catastrophe in Symmetrical Straight Double-Edged Cutting

You

Zhu

et al. 2022

Metals

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The chip-splitting catastrophe (CSC) generated by symmetrical cutting with a straight double-edged tool will lead to a significant reduction in cutting force. This has enormous potential for energy-saving machining and for the design of energy efficient cutting tools. The premise of the utilization is to establish a mathematical model that can predict the critical conditions of CSC. However, no related literature has studied the prediction model of CSC. Therefore, this paper proposes an experimental method based on catastrophe theory to establish a model of CSC bifurcation set equations that can predict critical conditions. A total of 355 groups of experiments are conducted to observe the critical conditions of CSC in symmetrical straight double-edged cutting, and 22 groups of experimental data of the critical conditions were acquired. The modeling process is converted into the optimal solution of the function coefficient value when the mapping function from a set of actual control parameters to theoretical control parameters (u, v, w) is a linear function. The bifurcation set equation of CSC is established, which can predict CSC in the symmetrical cutting of a straight double-edged turning tool with any combination of edge angle and rake angle. With verification, it is found that the occurrence of CSC has obvious regularity, and the occurrence of CSC will lead to a maximum reduction of 64.68% in the specific cutting force. The predicted values of the critical cutting thickness for the CSC of the established equation are in good agreement with the experimental results (the average absolute error is 5.34%). This study lays the foundation for the energy-saving optimization of tool geometry and process parameters through the reasonable utilization of CSC.

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Experimental research on the critical conditions and critical equation of chip splitting when turning a C45E4 disc workpiece symmetrically with a high-speed steel double-edged turning tool

Cited by 2 publications

References 29 publications

Numerical Analysis of Surface Integrity in Parallel Turning Process Part II: Influence of Cutting Tool Rake Angle

Numerical Analysis of Surface Integrity in Parallel Turning Process Part II: Influence of Cutting Tool Rake Angle

Experimental Modeling of the Bifurcation Set Equation of the Chip-Splitting Catastrophe in Symmetrical Straight Double-Edged Cutting

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