Mechanics and Modeling of Chip Formation in Machining of MMC

Shin, Yung C.; Dandekar, Chinmaya R.

doi:10.1007/978-0-85729-938-3_1

Cited by 16 publications

(10 citation statements)

References 94 publications

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“…The nature of swarf formation and types of obtained swarf are largely determined by properties of material to be machined. The mechanism of process of swarf formation is governed by the patterns of deformation and destruction [6][7][8][9]. Destruction of machined material along the cut line is a prerequisite for swarf formation during cutting.…”

Section: Methodsmentioning

confidence: 99%

Mathematical Model of State of Stress in Cutting Area During Synthegran Machining

Ivanova

Tyukpiekov

2018

Proceedings of the 4th International Conference on Industrial Engineering

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Synthegran is composite material compounded of an epoxy binder and high-strength mineral filler. Fillers include different fractions of granite macadam with various grain sizes from 1 to 15 mm. Synthegran is used in order to substitute iron casting employed for basic parts of lathes, machines, and tools. Nowadays, the behavior of this material in the process of manufacturing parts and assemblies from it and while machining has not been sufficiently studied yet. Synthegran machining has several features distincting it from similar metal machining. It is explained by characteristic properties and the structure of material to be machined. This article deals with the mechanism of swarf formation during machining of the mentioned composite by a blade cutting tool. Due to the material being fragile, the fundamental principles of the theory of fracture mechanics as well as the theory of metal cutting were analyzed. The mathematical models of cutting process, which allow us to determine state of stress in cutting area and predict the quality of synthegran surface, were proposed. The research demonstrated that peak normal and shear stresses during machining occur below the cutting surface. Thus, during swarf formation, the crack will spread deep into a material surface. Consequently, the quality of the composite surface is fully determined by a trajectory of crack propagation under the formation of discontinuous chip.

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Section: Methodsmentioning

confidence: 99%

Mathematical Model of State of Stress in Cutting Area During Synthegran Machining

Ivanova

Tyukpiekov

2018

Proceedings of the 4th International Conference on Industrial Engineering

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“…Figure 12 depicted that cutting force will decrease while reducing the depth of cut and increasing some amount of cutting force, it is due to increment of cutting speed produces the temperature in the cutting zone, which ultimately leads to thermal softening. Make chips easier to form, so the cutting force will be reduced [52]. As the depth of cut increases and the feed rate increases, the cutting force tends to increase greatly, as shown in Figs.…”

Section: Assessment Of Interactive Effect Through Contour Plots For Sicp/al 50%mentioning

confidence: 99%

Modeling and optimization of cutting forces and effect of turning parameters on SiCp/Al 45% vs SiCp/Al 50% metal matrix composites: a comparative study

Laghari

2021

SN Appl. Sci.

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In this study, the proposed experimental and second-order model for the cutting forces were developed through several parameters, including cutting speed, feed rate, depth of cut, and two varying content of SiCp. Cutting force model was developed and optimized through RSM and compared for two different percentages of components SiCp/Al 45% and SiCp/Al 50%. ANOVA is used for Quantitative evaluation, the main effects plot along with the evaluation using different graphs and plots including residual analysis, contour plots, and desirability functions for cutting forces optimization. It provides the finding for choosing proper parameters for the machining process. The plots show that during increment with depth of cut in proportion with feed rate are able to cause increments in cutting forces. Higher cutting speed shows a positive response in both the weight percentage of SiCp by reducing the cutting force because of higher cutting speed increases. A very fractional increasing trend of cutting force was observed with increasing SiCp weight percentages. Both of the methods such as experiment and model-predicted results of SiCp/Al MMC materials were thoroughly evaluated for analyzing cutting forces of SiCp/Al 45%, and SiCp/Al 50%, as well as calculated the error percentages also found in an acceptable range with minimal error percentages. Article Highlights This study focuses on the effect of cutting parameters as well as different percentage of SiC particles on the cutting forces, while comparing the results of both SiC particles such as SiCp/Al 45%, and SiCp/Al 50% the result shows that there isn’t fractional amount of impact on the cutting force with nominal increasing percentages of SiC particles. Cutting speed in machining process of SiCp/Al shows positive response in reducing the cutting forces, however, increasing amount of depth of cut followed by increasing feed rate creates fluctuations in cutting force and thus increases the cutting force in the cutting process. The developed RSM mathematical model which is based on the box Behnken design show excellent competence for predicting and suggesting the machining parameters for both SiCp/Al 45%, and SiCp/Al 50% and the RSM mathematical model is feasible for optimization of the machining process with good agreement to experimental values.

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“…A higher amount of feed rate during the cutting process changes the spring-like coils in C-type coils and the curl radius increases. It is because the increment in feed rate reduces the coefficient of deformation, because of that chip coiling radius increases, at the same time increment in cutting speed increases the cutting zone temperature and improve the plasticity of SiCp/Al which provide easy machining process to form curling chips and reduce the cutting force [7,49].…”

Section: Effect Of Cutting Parameters On Chip Morphologymentioning

confidence: 99%

“…In the cutting process, the tool wear is severe, and the defects on the machined surface are more. These factors seriously hinder the several application of the SiCp/Al composite material [7,8].…”

Section: Introductionmentioning

confidence: 99%

Study of Machining Process of SiCp/Al Particle Reinforced Metal Matrix Composite Using Finite Element Analysis and Experimental Verification

Laghari

2020

Materials

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In this paper, a two-dimensional orthogonal cutting simulation model of SiCp/Al composite was established. The geometry and material constitutive model of the particle, the matrix, and the interface layer have been modeled respectively. In view of the distribution of the particles in the matrix, this paper proposed respectively a two-dimensional particle random distribution to simulate particles randomly distributed in the matrix. Then, the cutting state of SiC reinforced particles was analyzed, the novel approach was adopted the geometric shapes of SiC particles in this study is taken as an oval shape. Three different locations of SiC particle relative to the cutting tool path were simulated to analyze the cutting state such as particle removal. The interface layer was introduced to the case that the particle was on the cutting path to study the influence on the stress and strain transfer. Through the post-processing of simulation results, the influence of interface property on the composite reinforcement effect was studied quantificationally. Finally, the cutting process of SiCp/Al composite material was simulated. This paper studied the influence on the machined surface morphology, chip morphology, stress distribution, and cutting force of many factors of the cutting speed and the cutting thickness. The single factor orthogonal cutting experiment was designed the influence of cutting speed and feed rate on the cutting force. The cutting force results of the experiment and the simulation were compared through the deviation analysis, which verified the simulation model.

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Mechanics and Modeling of Chip Formation in Machining of MMC

Cited by 16 publications

References 94 publications

Mathematical Model of State of Stress in Cutting Area During Synthegran Machining

Mathematical Model of State of Stress in Cutting Area During Synthegran Machining

Modeling and optimization of cutting forces and effect of turning parameters on SiCp/Al 45% vs SiCp/Al 50% metal matrix composites: a comparative study

Study of Machining Process of SiCp/Al Particle Reinforced Metal Matrix Composite Using Finite Element Analysis and Experimental Verification

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