Modeling of chip–tool interface friction to predict cutting forces in machining of Al/SiCp composites

Dabade, Uday A.; Dapkekar, Dilip; Joshi, Suhas S.

doi:10.1016/j.ijmachtools.2009.03.003

Cited by 102 publications

(40 citation statements)

References 17 publications

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“…There are a few studies focused on the prediction model of cutting forces in cutting or conventional grinding of metal matrix composites (MMCs) [6][7][8][9][10][11][12]. Kishawy et al [6] presented an energy-based analytical force model in orthogonal cutting of SiCp/Al composites to predict cutting forces.…”

Section: Introductionmentioning

confidence: 99%

“…Davim [8] presented a preliminary experimental study based on Merchant theory, in which the chip compression ratio, shear angle, shear strain, shear strain rate, normal stress, and shear stress were evaluated. Dabade et al [9] developed a cutting force prediction model in turning SiCp/Al composites, in which the frictional characteristics of chip-tool and work-tool interfaces were considered. Sikder et al [10] presented an analytical prediction force model in turning SiCp/Al composites.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

A model for grinding forces prediction in ultrasonic vibration assisted grinding of SiCp/Al composites

Zhou

Zheng

2016

Int J Adv Manuf Technol

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Ultrasonic vibration assisted grinding is an advanced method for machining difficult-to-process materials such as SiCp/Al composites. This paper presents a mechanics model for predicting grinding forces in ultrasonic vibration assisted grinding of SiCp/Al composites. It consists of side grinding force model and end grinding force model. In side grinding force model, the major components are the normal force and tangential force in which the analytical expressions for the chip formation force based on Rayleigh's probability density function, the frictional force, and the particle fracture force based on Griffith theory are established, respectively. In contrast, the axial force developed based on the indentation theory is the major component in end grinding force model. The coefficients in the proposed grinding force model were obtained through two groups of orthogonal experiments. Based on the mechanics prediction model, the relationship between grinding forces and process variables were predicted. At last, two groups of single factor experiments were conducted to verify the proposed grinding force model and experimental results were found to agree well with predicted results.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A model for grinding forces prediction in ultrasonic vibration assisted grinding of SiCp/Al composites

Zhou

Zheng

2016

Int J Adv Manuf Technol

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“…And, the machining Al/SiCp composites presents brittle removal mechanism basically. Therefore, the friction coefficient between the chip and the rake face is approximately constant value and the average cutting force cannot obviously change with increasing the cutting speed (Dabade et al, 2009). In addition, it can be seen from Fig. 14 that the roughness value of 6063Al/SiCp composite is significantly higher than that of 2024Al/SiCp composite.…”

Section: Evaluation Of Surface Roughness Of Al/sic Compositesmentioning

confidence: 99%

Defects formation mechanism and evaluation of surface roughness in machining Al/SiCp composites

Duan

Sun

Zhan

et al. 2018

JAMDSM

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During machining Al/SiCp composites, the machined surface takes on many defects such as grooves, pits, voids and protuberances, which greatly affect the characterization parameters of surface topography. However, a detailed investigation of the formation mechanism of surface defects in machining Al/SiCp composites is still lacking, and few surface roughness evaluation methods have been developed for separating the surface defects from roughness. In this paper, the formation mechanism of surface defects is revealed, and a roughness extraction method based on DT-CWT is established to extract the surface defects from roughness and conduct a roughness evaluation on the machined surface of Al/SiCp composites. Compared with the least-square method and Gaussian filter, the roughness extraction method based on DT-CWT has higher stability and can effectively distinguish between surface roughness and surface defects. According to the surface roughness evaluation based on the roughness extraction method, it is found that the surface roughness value of 2024Al/SiCp composite is lower compared to 6063Al/SiCp composite.

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“…Li et al [8][9][10] had developed a theoretical cutting force model of oblique cutting for helical end mill by incorporating workpiece properties, tool geometry, and cutting conditions. The theoretical modeling explains the cutting mechanism and material constitutive flow principle; however, it makes some simplifications and complicates analytical calculations with massive experiments, low accuracy, and narrow application scope.…”

Section: Introductionmentioning

confidence: 99%

Prediction and Experimental Validation of Cutting Force for Bull-Nose End Mills with Lead Angle

Gao

Luo

et al. 2014

Advances in Mechanical Engineering

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This study focuses on cutting force predictions with the tool-workpiece inclination angle in bull-nose milling based on the semimechanistic force model. By analyzing kinematics and mechanics of the bull-nose end mills during cutting, force expressions including lead angle are stated and the model is exerted on each discrete element as oblique cutting with coordinate transformation and numerical integration to obtain the dynamic cutting force components. An improved identification method considering speed variations along the tool axis is applied to calibrate coefficients. Coefficients are regarded as the function of each elemental elevation. Then, a geometry-based method to acquire cutter workpiece engagement (CWE) is proposed. Also acquisition of accurate start and exit angles on each slice is deliberated elaborately for cutters with lead or tilt angle in milling processes. Thereby, to verify the validity of the force prediction model and start-exit angle acquisition method, experiments with variable lead angles are conducted under different axial immersions. The results reveal that the presented model and approaches can predict cutting forces with high accuracy. Finally, the cutting force components under different cutter postures and conditions are analyzed to provide instructions for parameter selections.

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Modeling of chip–tool interface friction to predict cutting forces in machining of Al/SiCp composites

Cited by 102 publications

References 17 publications

A model for grinding forces prediction in ultrasonic vibration assisted grinding of SiCp/Al composites

A model for grinding forces prediction in ultrasonic vibration assisted grinding of SiCp/Al composites

Defects formation mechanism and evaluation of surface roughness in machining Al/SiCp composites

Prediction and Experimental Validation of Cutting Force for Bull-Nose End Mills with Lead Angle

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