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The energy efficiency in metal cutting is, sometimes, very low. Recent studies show that the energy consumed for detaching chips represents only about 15% of the total energy involved in material machining. The available solutions for energy optimization in cutting processes mentioned are the improvement of manufacturing equipment, the optimization of processes, and appropriate production scheduling. Already-performed research shows that to increase energy efficiency, the cutting force must be reduced, for example, by reducing the depth of the cut and by increasing the feed rate. However, this is applicable when the cutting force is quasi-constant during the process, which is not the case for gear teeth cutting when the cutting force significantly varies. The present paper proposes a new solution for energy efficiency increase in gear teeth cutting, namely, the smoothing of the cutting force variation during the machining process, by keeping the area of the detached chip section quasi-constant during the cutting process. This can be reached by replacing the constant rolling feed, currently used in gear teeth cutting, with a rolling feed that varies after an appropriate law. An algorithm dedicated to implementing this solution has been developed. It uses graphical modeling in CATIA to find the variation in the detached chip area. Original MatLab R2018a applications were developed (i) to identify the analytical form of the law that approximates this variation and (ii) to find the variation law of the feed during the rolling motion, if imposing a constant area of the detached chip. The algorithm was successfully applied in the cases of toothing with a rack tool (by slotting) and with a pinion cutter (by slotting and turning). A technical solution for method implementation in practice is also presented.
The energy efficiency in metal cutting is, sometimes, very low. Recent studies show that the energy consumed for detaching chips represents only about 15% of the total energy involved in material machining. The available solutions for energy optimization in cutting processes mentioned are the improvement of manufacturing equipment, the optimization of processes, and appropriate production scheduling. Already-performed research shows that to increase energy efficiency, the cutting force must be reduced, for example, by reducing the depth of the cut and by increasing the feed rate. However, this is applicable when the cutting force is quasi-constant during the process, which is not the case for gear teeth cutting when the cutting force significantly varies. The present paper proposes a new solution for energy efficiency increase in gear teeth cutting, namely, the smoothing of the cutting force variation during the machining process, by keeping the area of the detached chip section quasi-constant during the cutting process. This can be reached by replacing the constant rolling feed, currently used in gear teeth cutting, with a rolling feed that varies after an appropriate law. An algorithm dedicated to implementing this solution has been developed. It uses graphical modeling in CATIA to find the variation in the detached chip area. Original MatLab R2018a applications were developed (i) to identify the analytical form of the law that approximates this variation and (ii) to find the variation law of the feed during the rolling motion, if imposing a constant area of the detached chip. The algorithm was successfully applied in the cases of toothing with a rack tool (by slotting) and with a pinion cutter (by slotting and turning). A technical solution for method implementation in practice is also presented.
This study investigates the influence of various tool coatings, cutting speeds, and feed per tooth values on cutting forces during the CNC milling of Medium Density Fiberboard (MDF). The coatings tested include reference, TripleSi, Hyperlox, DLC, and lapped coatings. Experiments were conducted using an SCM Morbidelli m100 CNC milling machine under controlled conditions. Cutting speeds were set at 8, 10, and 12 m/s, while feed per tooth values were varied at 0.1, 0.2, and 0.3 mm. Cutting forces were measured using a three-axis piezoelectric dynamometer Kistler, and the data were analyzed to determine the impact of these variables on cutting performance. The results revealed that while cutting speed had a minimal effect on cutting forces, feed per tooth significantly influenced them, with higher values of feed per tooth leading to increased forces. Among the coatings, lapped and TripleSi exhibited the lowest cutting forces, whereas DLC showed the highest. Statistical analysis, including ANOVA and Scheffé tests, confirmed the significant differences between the coatings and highlighted the superior performance of the lapped and TripleSi coatings in reducing cutting forces.
The manufacturing of work parts made of powder (sintered) steels is currently widespread in industry, as it provides minimal processing allowances and high dimensional accuracy, as well as the required properties and unconventional chemical composition. At the same time, their low tensile or bending strength must be considered a serious disadvantage. In order to minimize these disadvantages, a number of strengthening technologies are used, among which is the infiltration of porous base materials with metal alloys. In this study, the details of finish turning of sintered iron-graphite-based steel infiltrated with tin bronze with molybdenum disulfide addition are considered. Changes in the shape of chips and their geometric features, as well as the 3D parameters and topography features of the surface machined, are presented after finish turning with AH8015 carbide inserts. The cutting speed (vc) and feed rate (f) were used as variable parameters. It was found that when turning the powder steels under study, the chips took the shape of small fragments or element chips, including segmented chips. For quenching steel, the formation of irregular lamellae was observed and for the initial state, a serrated chip was registered. For the initial state, a reduction in Kb values was observed in the range of the vc of 50–100 m/min and f of 0.05–0.075 mm/rev, and for quenching in the range of 225–250 m/min and 0.05–0.075 mm/rev. Compared to the initial state, for quenching, depending on the cutting parameters, a 14% reduction in the chip spreading ratio Kb or an increase from 2 to 32% was registered. For the initial state and quenching, a decrease in the Sp and Sv parameters was achieved in the range of the vc of 200–250 m/min and f of 0.05–0.075 mm/rev, and there was an increase in the range of 50–150 m/min and 0.125–0.15 mm/rev. Compared to the initial state, an increase in the Sz parameter from 10 to 35% was observed for quenching. On the surfaces machined with vc = 50 m/min and f = 0.05 mm/rev, waves and single significant peaks were observed. On the other hand, vc = 250 m/min and f = 0.15 mm/rev provided classical feed tracks in the form of valleys and irregular ridges on the surfaces machined. The test results can be useful in the design and manufacturing of industrial parts made of powder steels.
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