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Kowalczyk M. Analysis of Cutting Forces and Geometric Surface Structures in the Milling of NiTi Alloy. Materials (Basel) 2024; 17:488. [PMID: 38276427 PMCID: PMC10817664 DOI: 10.3390/ma17020488] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/18/2023] [Revised: 01/16/2024] [Accepted: 01/18/2024] [Indexed: 01/27/2024]
Abstract
This paper presents a study of the total cutting force used and selected parameters of the geometric structure of the surface (e.g., Sa, Sz) during the end milling process of NiTi alloy. The input parameters included are cutting speed (vc), feed per tooth (fz), and radial depth of cut (ae). A Box-Behnken experimental design was employed to conduct the research. The obtained experimental results were utilized within the framework of a response surface methodology (RSM) to develop mathematical and statistical models capable of predicting cutting force components and selected 3D surface parameters. These models provide valuable insights into the relationships between the cutting parameters and the output variables, facilitating the optimization of the NiTi alloy milling process. The findings of this study contribute to a better understanding of the behavior of NiTi alloy during the milling process and offer information for process optimization. By employing a Box-Behnken experimental design, it was possible to investigate the effects of different parameter combinations on the components of total cutting force and selected 3D surface parameters according to ISO 25178, thus aiding in the identification of optimal milling conditions to achieve desired outcomes in the machining of NiTi alloy.
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Affiliation(s)
- Małgorzata Kowalczyk
- Chair of Production Engineering, Faculty of Mechanical Engineering, Cracow University of Technology, Jana Pawła II 37 Avenue, 31-864 Krakow, Poland
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2
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Biruk-Urban K, Bere P, Józwik J. Machine Learning Models in Drilling of Different Types of Glass-Fiber-Reinforced Polymer Composites. Polymers (Basel) 2023; 15:4609. [PMID: 38232045 PMCID: PMC10708451 DOI: 10.3390/polym15234609] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/12/2023] [Revised: 11/26/2023] [Accepted: 12/01/2023] [Indexed: 01/19/2024] Open
Abstract
The aim of the research presented in this paper was to simulate the relationship between selected technological drilling parameters (cutting speed, vc, and feed per tooth, fz) and cutting forces and the delamination in machining of a new glass-fiber-reinforced polymer (GFRP) composite. Four different types of new materials were manufactured with the use of a specially designed pressing device and differed in the fiber type (plain and twill woven materials) and weight fraction (wf) ratio, but they had the same number of layers and the same stacking sequence. A vertical machining center Avia VMC800HS was used for drilling holes with a two-edge carbide diamond coated drill. Measurements of the cutting force Fz in the drilling process conducted with variable technological parameters were carried out on a special test stand, 9257B, from Kistler. The new ink penetration method, involving covering the drilled hole surface with a colored liquid that spreads over the inner surface of the hole showing damage, was used to determine the delamination area. The cause-and-effect relationship between the drilling parameters was simulated with the use of five machine learning (ML) regression models (Linear Regression; Decision Tree Regressor; Decision Tree Regressor with Ada Boost; XGBRF Regressor; Gradient Boosting Regressor). Gradient Boosting Regressor results showed that the feed per tooth had the greatest impact on delamination-the higher the feed was, the greater the delamination became. Push-out delamination factors had higher values for materials that were made of plain woven fibers. The lowest amplitude of the cutting force component Fz was obtained for the lowest tested feed per tooth of 0.04 mm for all tested materials, with the lowest values obtained for the materials with twill fibers.
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Affiliation(s)
- Katarzyna Biruk-Urban
- Department of Production Engineering, Mechanical Engineering Faculty, Lublin University of Technology, 20-618 Lublin, Poland;
| | - Paul Bere
- Department of Manufacturing Engineering, Faculty of Industrial Engineering, Robotics and Production Management, Technical University of Cluj-Napoca, Memorandumului 28, 400114 Cluj-Napoca, Romania;
| | - Jerzy Józwik
- Department of Production Engineering, Mechanical Engineering Faculty, Lublin University of Technology, 20-618 Lublin, Poland;
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3
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Song X, Wu W, Zhao Y, Cheng Y, Liu L. Structural Design and Optimization of the Milling Force Measurement Tool System Embedded with Thin-Film Strain Sensors. Micromachines (Basel) 2023; 14:2133. [PMID: 38138302 PMCID: PMC10745591 DOI: 10.3390/mi14122133] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/22/2023] [Revised: 11/13/2023] [Accepted: 11/19/2023] [Indexed: 12/24/2023]
Abstract
A milling force measurement tool system is designed with an elastic beam structure, which is divided into a two-end ring hoop compression sensor mode and a two-end square hoop compression sensor mode to improve the strain sensitivity. A simplified mechanical model of the elastic beam is established, and the relationship between the strain and force of the elastic beam under the action of three cutting force components is investigated, which can act a guide for subsequent milling force measurement tool system calibration tests. Thin-film strain sensors occupy a central position in the milling force measurement tool system, which consists of a substrate, transition layer, insulating layer and resistance grid layer. The resistance grid layer has a particularly significant effect on the thin-film strain sensor's performance. In order to further improve the sensitivity of thin-film strain sensors, the shapes of the substrate, the transition layer, the insulating layer and the resistance grid layer are optimized and studied. A new thin-film strain sensor is designed with a resistance grid beam constructed from an insulating layer and a resistive grid layer double-end-supported on the transition layer. The flow of the wet-etching process of thin-film strain sensors is studied and samples are obtained. The surface microforms of the sensor samples are observed by extended depth-of-field microscopy, confocal microscopy and atomic force microscopy. It can be seen that the boundary of the resistance grid layer pattern is tidy and has high dimensional accuracy, thus enabling the basic achievement of the expected effect of the design. The electrical performance of the samples is tested on an experimental platform that we built, and the results show that the resistive sensitivity coefficient of the samples is increased by about 20%, to 51.2%, compared with that of the flat thin-film strain sensor, which fulfils the design's requirements.
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Affiliation(s)
| | - Wenge Wu
- School of Mechanical Engineering, North University of China, Taiyuan 030051, China; (X.S.); (Y.Z.); (Y.C.); (L.L.)
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4
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Kónya G, Kovács ZF. Effects of Machining Parameters and Tool Reconditioning on Cutting Force, Tool Wear, Surface Roughness and Burr Formation in Nickel-Based Alloy Milling. Materials (Basel) 2023; 16:7140. [PMID: 38005070 PMCID: PMC10672182 DOI: 10.3390/ma16227140] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/11/2023] [Revised: 10/31/2023] [Accepted: 11/08/2023] [Indexed: 11/26/2023]
Abstract
Nickel-based superalloys are among the most difficult materials to machine because they have high thermal strength, they are prone to hardening, carbides severely abrade the tool, and they have very poor thermal conductivity. Slot milling is a specific issue as it is characterized by rapid tool wear and frequent tool breakages. This is why reconditioned tools are frequently employed in industrial environments, as they can considerably decrease the expenses associated with tools. The chosen machining strategy also plays a crucial role in the tool's lifespan and the quality of the machined surface, making it essential to select the appropriate strategy. Hence, the authors have opted for two conventional trochoidal strategies, namely the circular and swinging toolpath, along with a contemporary toolpath known as the Autodesk Inventor HSM Adaptive strategy. The authors investigated the effects of technological parameters and toolpaths on cutting forces, tool wear, surface roughness and burr formation on machined edges. The results show that lower cutting parameters and adaptive strategies lead to the smallest tool loads, tool wear, the best quality of surface roughness and burr formation on machined edges.
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Affiliation(s)
- Gábor Kónya
- Department of Innovative Vehicles and Materials, GAMF Faculty of Engineering and Computer Science, John von Neumann University, Izsáki St. 10, H-6000 Kecskemét, Hungary;
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Shang P, Zhang H, Liu X, Yang Z, Liu B, Liu T. Cutting-Force Modeling Study on Vibration-Assisted Micro-Milling of Bone Materials. Micromachines (Basel) 2023; 14:1422. [PMID: 37512733 PMCID: PMC10384012 DOI: 10.3390/mi14071422] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/23/2023] [Revised: 07/10/2023] [Accepted: 07/11/2023] [Indexed: 07/30/2023]
Abstract
This study aims to enhance surgical safety and facilitate patient recovery through the investigation of vibration-assisted micro-milling technology for bone-material removal. The primary objective is to reduce cutting force and improve surface quality. Initially, a predictive model is developed to estimate the cutting force during two-dimensional (2D) vibration-assisted micro-milling of bone material. This model takes into account the anisotropic structural characteristics of bone material and the kinematics of the milling tool. Subsequently, an experimental platform is established to validate the accuracy of the cutting-force model for bone material. Micro-milling experiments are conducted on bone materials, with variations in cutting direction, amplitude, and frequency, to assess their impact on cutting force. The experimental results demonstrate that selecting appropriate machining parameters can effectively minimize cutting force in 2D vibration-assisted micro-milling of bone materials. The insights gained from this study provide valuable guidance for determining cutting parameters in vibration-assisted micro-milling of bone materials.
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Affiliation(s)
- Peng Shang
- School of Mechanical Engineering, Hebei University of Technology, Tianjin 300400, China
| | - Huaiqing Zhang
- School of Mechanical Engineering, Hebei University of Technology, Tianjin 300400, China
| | - Xiaopeng Liu
- School of Mechanical Engineering, Hebei University of Technology, Tianjin 300400, China
| | - Zhuang Yang
- School of Mechanical Engineering, Hebei University of Technology, Tianjin 300400, China
| | - Bingfeng Liu
- School of Mechanical Engineering, Hebei University of Technology, Tianjin 300400, China
| | - Teng Liu
- School of Mechanical Engineering, Hebei University of Technology, Tianjin 300400, China
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Devi C, Mahalingam SK, Cep R, Kouril K. Effect of Cryo-Treated Cutting Tool End Milling on Custom 450 Stainless Steel. Materials (Basel) 2023; 16:4744. [PMID: 37445058 DOI: 10.3390/ma16134744] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/24/2023] [Revised: 06/26/2023] [Accepted: 06/27/2023] [Indexed: 07/15/2023]
Abstract
Custom 450 stainless steel is the most desirable material across industries due to its widespread application in the aerospace, defense and marine industries. Stainless-steel materials are challenging to deal with and fall into the list of hard-to-process materials due to their low heat conduction coefficient and high mechanical properties. In this research work, end milling was carried out on Custom 450 stainless steel machined using TiAlN coated with tungsten carbide inserts that have been cryo-treated (CT) for 24 h (24 h) and 36 h (36 h), as well as untreated (UT) inserts. The inserts were evaluated in terms of feed force, feed rate and consistent depth of cut (ap) at various spindle speeds (S). Also examined were the tool morphology, chip anatomy and surface morphology of cryo-treated material compared to untreated inserts at various responses to cutting force (Fx, Fy, Fz), cutting temperature (Tc), vibration and surface abrasion. For inserts that have been cryo-treated for 36 h, the feed force (Fx) value was 44% and 5% less compared to inserts treated for 24 h and in UT inserts, respectively. Furthermore, for 24-h and 36-h CT inserts, feed force (Fx) was 12% and 20% less compared to a UT insert. Using 24-h cryo-treated inserts as opposed to UT inserts significantly reduced the surface roughness by 20%. Cutting inserts that have undergone cryogenic treatment have been observed to exhibit longer cutting tool life due to less wear and friction on the cutting edges.
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Affiliation(s)
- C Devi
- Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Avadi 600062, India
| | - Siva Kumar Mahalingam
- Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Avadi 600062, India
| | - Robert Cep
- Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB-Technical University of Ostrava, 70800 Ostrava, Czech Republic
| | - Karel Kouril
- Institute of Manufacturing Technology, Faculty of Mechanical Engineering, Brno University of Technology, Technicka 2896/2, 61669 Brno, Czech Republic
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Yalçın B, Yüksel A, Aslantaş K, Der O, Ercetin A. Optimization of Micro-Drilling of Laminated Aluminum Composite Panel (Al-PE) Using Taguchi Orthogonal Array Design. Materials (Basel) 2023; 16:4528. [PMID: 37444842 DOI: 10.3390/ma16134528] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/24/2023] [Revised: 06/15/2023] [Accepted: 06/19/2023] [Indexed: 07/15/2023]
Abstract
Aluminum Matrix Composite (AMC) represents an innovative class of materials that is extensively utilized in industries such as automotive, defense, aerospace, structural engineering, sports, and electronics. This study investigates the thrust force, exit burr formation, changes in the micro-tool, and drilled hole diameters during the micro-drilling of an aluminum-polyethylene composite panel (Al-PE). The panel consists of 3501 series aluminum skin materials bonded to a polyethylene (PE) core. Micro-drilling test parameters were designed using Taguchi's L16 (42 23) orthogonal array. Tests were conducted with five control parameters: cutting speed with four levels (10 m/min, 20 m/min, 30 m/min, 40 m/min), feed rate with four levels (0.5 µm/rev, 1 µm/rev, 2 µm/rev, 4 µm/rev), the tool diameter with two levels (0.7 mm, 1 mm), and tool point angle with two levels (100°, 140°) using both AlTiN-coated and uncoated drills. The maximum thrust force (Fz), maximum burr height, and changes in both the drill tool and hole diameters were measured for analysis of variance (ANOVA). The results showed that, in terms of impact on Fz, tool point angle had the highest positive influence (64.54%) on the micro-drill at the entrance of composite (upper aluminum plate). The cutting speed had the highest positive influence (45.32%) on the tool in the core layer (PE core layer). The tool point angle also had the highest positive influence (68.95%) on the micro-drill at the lower layer of the composite (the lower aluminum plate). There was noticeable chip adhesion on the major cutting edge and nose area under micro-drilling conditions with higher thrust forces and burr height. The AlTiN coating had a positive effect on tool wear and hole diameter deviations, but it adversely affected the burr height.
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Affiliation(s)
- Bekir Yalçın
- Department of Mechanical Engineering, Faculty of Technology, Afyon Kocatepe University, Afyonkarahisar 03200, Turkey
| | - Ali Yüksel
- Department of Mechanical Engineering, Faculty of Technology, Afyon Kocatepe University, Afyonkarahisar 03200, Turkey
| | - Kubilay Aslantaş
- Department of Mechanical Engineering, Faculty of Technology, Afyon Kocatepe University, Afyonkarahisar 03200, Turkey
| | - Oguzhan Der
- Department of Marine Vehicles Management Engineering, Maritime Faculty, Bandırma Onyedi Eylul University, Bandırma 10200, Turkey
| | - Ali Ercetin
- Department of Naval Architecture and Marine Engineering, Maritime Faculty, Bandırma Onyedi Eylul University, Bandırma 10200, Turkey
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Liang L, Li S, Lan K, Wang J, Yu R. Fixed-Diamond Abrasive Wire-Saw Cutting Force Modeling Based on Changes in Contact Arc Lengths. Micromachines (Basel) 2023; 14:1275. [PMID: 37374860 DOI: 10.3390/mi14061275] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/29/2023] [Revised: 06/17/2023] [Accepted: 06/19/2023] [Indexed: 06/29/2023]
Abstract
Monocrystalline silicon is widely used in the semiconductor market, but its hard and brittle physical properties make processing difficult. Fixed-diamond abrasive wire-saw (FAW) cutting is currently the most commonly used cutting method for hard and brittle materials due to advantages such as narrow cutting seams, low pollution, low cutting force and simple cutting process. During the process of cutting a wafer, the contact between the part and the wire is curved, and the arc length changes during the cutting process. This paper establishes a model of contact arc length by analyzing the cutting system. At the same time, a model of the random distribution of abrasive particles is established to solve the cutting force during the cutting process, using iterative algorithms to calculate cutting forces and chip surface saw marks. The error between the experiment and simulation of the average cutting force in the stable stage is less than 6%, and the errors with respect to the central angle and curvature of the saw arc on the wafer surface are less than 5% between the experiment and simulation. The relationship between the bow angle, contact arc length and cutting parameters is studied using simulations. The results show that the variation trend of the bow angle and contact arc length is consistent, increasing with an increase in the part feed rate and decreasing with an increase in the wire velocity.
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Affiliation(s)
- Lie Liang
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Shujuan Li
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Kehao Lan
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Jiabin Wang
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Ruijiang Yu
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
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Yu R, Li S, Zou Z, Liang L. Mathematical Modeling and Experimental Study of Cutting Force for Cutting Hard and Brittle Materials in Fixed Abrasive Trepanning Drill. Micromachines (Basel) 2023; 14:1270. [PMID: 37374855 DOI: 10.3390/mi14061270] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/24/2023] [Revised: 06/14/2023] [Accepted: 06/16/2023] [Indexed: 06/29/2023]
Abstract
Hard and brittle materials have excellent physical and mechanical performance, which are widely applied in the fields of microelectronics and optoelectronics. However, deep-hole machining of hard and brittle materials is very difficult and inefficient due to the high hardness and brittleness of these materials. To improve the quality and efficiency of deep-hole machining of hard and brittle materials, according to the brittle crack fracture removal mechanism of hard and brittle materials and the cutting model of the trepanning cutter, an analytical cutting force prediction model of hard and brittle materials processed using a trepanning cutter is established. This experimental study of K9 optical glass machining shows that as the feeding rate increase, the cutting force increase, and as the spindle speed increase, the cutting force decrease. By comparing and verifying the theoretical and experimental values, the average errors of axial force and torque are 5.0% and 6.7%, respectively, and the maximum error is 14.9%. This paper analyzes the reasons for the errors. The results indicate that the cutting force theoretical model can be used to predict the axial force and torque of machining hard and brittle materials under the same conditions, which provides a theory for optimizing machining process parameters.
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Affiliation(s)
- Ruijiang Yu
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Shujuan Li
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Zhengkang Zou
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Lie Liang
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
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Li G, Xie W, Wang H, Chai Y, Zhang S, Yang L. Optimizing Processing Parameters and Surface Quality of TC18 via Ultrasonic-Assisted Milling (UAM): An Experimental Study. Micromachines (Basel) 2023; 14:1111. [PMID: 37374696 DOI: 10.3390/mi14061111] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/22/2023] [Revised: 05/17/2023] [Accepted: 05/22/2023] [Indexed: 06/29/2023]
Abstract
This study conducted longitudinal ultrasonic-assisted milling (UAM) tests and optimized a combination of milling technological parameters to achieve high-quality machining of TC18 titanium alloy. The motion paths of the cutter under the coupled superposition states of longitudinal ultrasonic vibration and end milling were analyzed. Based on the orthogonal test, the cutting forces, cutting temperatures, residual stresses, and surface topographical patterns of TC18 specimens under different UAM conditions (cutting speeds, feeds per tooth, cutting depths, and ultrasonic vibration amplitudes) were examined. The differences between ordinary milling and UAM in terms of machining performance were compared. Using UAM, numerous characteristics (including variable cutting thickness in the cutting area, variable cutting front angles of the tool, and the lifting of the cuttings by the tool) were optimized, reducing the average cutting force in all directions, lowering the cutting temperature, increasing the surface residual compressive stress, and significantly improving the surface morphology. Finally, fish scale bionic microtextures with clear, uniform, and regular patterns were formed on the machined surface. High-frequency vibration can improve material removal convenience, thus reducing surface roughness. The introduction of longitudinal ultrasonic vibration to the end milling process can overcome the limitations of traditional processing. The optimal combination of UAM parameters for titanium alloy machining was determined through the end milling orthogonal test with compound ultrasonic vibration, which significantly improved the surface quality of TC18 workpieces. This study provides insightful reference data for subsequent machining process optimization.
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Affiliation(s)
- Guangxi Li
- Henan Province Engineering Research Center of Ultrasonic Technology Application, Pingdingshan University, Pingdingshan 467000, China
| | - Weibo Xie
- School of Intelligent Manufacturing and Transportation, Chongqing Vocational Institute of Engineering, Chongqing 402260, China
| | - Hongtao Wang
- School of Mechanical and Power Engineering, Zhengzhou University, Zhengzhou 450001, China
| | - Yongbo Chai
- Henan Province Engineering Research Center of Ultrasonic Technology Application, Pingdingshan University, Pingdingshan 467000, China
| | - Shaolin Zhang
- School of Mechanical and Power Engineering, Zhengzhou University, Zhengzhou 450001, China
| | - Liquan Yang
- Henan Province Engineering Research Center of Ultrasonic Technology Application, Pingdingshan University, Pingdingshan 467000, China
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The Ho QN, Do TT, Minh PS. Studying the Factors Affecting Tool Vibration and Surface Quality during Turning through 3D Cutting Simulation and Machine Learning Model. Micromachines (Basel) 2023; 14:mi14051025. [PMID: 37241649 DOI: 10.3390/mi14051025] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/19/2023] [Revised: 05/01/2023] [Accepted: 05/09/2023] [Indexed: 05/28/2023]
Abstract
Nowadays, machining products, especially by turning methods, are more and more popular and require high-quality. With the development of science and technology, especially numerical computing technology and control technology, the application of these technological achievements to improve productivity and product quality has become increasingly essential. This study applies a simulation method considering the affecting factors of the vibration of the tool and the surface quality of the workpiece during turning. The study simulated and analyzed the characteristics of the cutting force and oscillation of the toolholder when stabilizing; at the same time, the study also simulated the behavior of the toolholder under the effect of cutting force and determined the finished surface quality through simulation. Additionally, the study utilized a machine learning model to examine the relationship between the toolholder length, cutting speed, feed rate, wavelength and surface roughness. The study found that tool hardness is the most crucial factor, and if the toolholder length exceeds the critical length, it leads to a rapid increase in roughness. In this study, the critical toolholder length was determined to be 60 mm, and this resulted in a corresponding surface roughness (Rz) of approximately 20 µm.
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Affiliation(s)
- Quang Ngoc The Ho
- Faculty of Mechanical Engineering, HCMC University of Technology and Education, Ho Chi Minh City 71307, Vietnam
- Faculty of Engineering and Technology, Nguyen Tat Thanh University, Ho Chi Minh City 70000, Vietnam
| | - Thanh Trung Do
- Faculty of Mechanical Engineering, HCMC University of Technology and Education, Ho Chi Minh City 71307, Vietnam
| | - Pham Son Minh
- Faculty of Mechanical Engineering, HCMC University of Technology and Education, Ho Chi Minh City 71307, Vietnam
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12
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Liang L, Li S, Lan K, Yu R, Wang J, Zhao W. Experimental Study on the Influence of Wire-Saw Wear on Cutting Force and Silicon Wafer Surface. Materials (Basel) 2023; 16:ma16103619. [PMID: 37241246 DOI: 10.3390/ma16103619] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/05/2023] [Revised: 05/01/2023] [Accepted: 05/07/2023] [Indexed: 05/28/2023]
Abstract
Hard and brittle materials such as monocrystalline silicon still occupy an important position in the semiconductor industry, but hard and brittle materials are difficult to process because of their physical properties. Fixed-diamond abrasive wire-saw cutting is the most widely used method for slicing hard and brittle materials. The diamond abrasive particles on the wire saw wear to a certain extent, which affects the cutting force and wafer surface quality in the cutting process. In this experiment, keeping all the given parameters unchanged, a square silicon ingot is cut repeatedly with a consolidated diamond abrasive wire saw until the wire saw breaks. The experimental results show that the cutting force decreases with the increase in cutting times in the stable grinding stage. The wear of abrasive particles starts at the edges and corners, and the macro failure mode of the wire saw is fatigue fracture. The fluctuation of the wafer surface profile gradually decreases. The surface roughness of wafer is steady during the wear steady stage, and the large damage pits on the wafer surface are reduced in the whole process of cutting.
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Affiliation(s)
- Lie Liang
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Shujuan Li
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Kehao Lan
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Ruijiang Yu
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Jiabin Wang
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
| | - Wen Zhao
- School of Mechanical and Precision Instrument Engineering, Xi'an University of Technology, Xi'an 710048, China
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13
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Dong Z, Zhang C, Liu Z, Zhao Y, Xing K, Guo W. A Wire Bow Model of Diamond Wire Sawing with Asymmetric Arc Hypothesis. Micromachines (Basel) 2023; 14:mi14051004. [PMID: 37241627 DOI: 10.3390/mi14051004] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/29/2023] [Revised: 05/04/2023] [Accepted: 05/04/2023] [Indexed: 05/28/2023]
Abstract
Diamond wire sawing is the main processing method for hard and brittle materials, but the unreasonable matching of process parameters will reduce its cutting ability and stability. In this paper, the asymmetric arc hypothesis of a wire bow model is proposed. Based on this hypothesis, an analytical model of the wire bow between the process parameters and the wire bow parameters was established and verified with a single-wire cutting experiment. The model considers the asymmetry of the wire bow in diamond wire sawing. The tension at both ends of the wire bow is called the endpoint tension; by calculating the difference in tension between the two ends, a reference for the cutting stability and a tension range for the selection of the diamond wire were provided. The model was used to calculate the wire bow deflection and the cutting force, providing theoretical guidance for the matching of process parameters. Based on the theoretical analysis of the cutting force, endpoint tension and wire bow deflection, the cutting ability, cutting stability, and the risk of wire cutting were predicted.
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Affiliation(s)
- Zhikui Dong
- School of Mechanical Engineering, Yanshan University, No. 438 West Hebei Avenue, Qinhuangdao 066004, China
| | - Chenpu Zhang
- School of Mechanical Engineering, Yanshan University, No. 438 West Hebei Avenue, Qinhuangdao 066004, China
| | - Ziliang Liu
- School of Mechanical Engineering, Yanshan University, No. 438 West Hebei Avenue, Qinhuangdao 066004, China
| | - Yanheng Zhao
- School of Mechanical Engineering, Yanshan University, No. 438 West Hebei Avenue, Qinhuangdao 066004, China
| | - Ke Xing
- Plant 4, Fuyang Industrial Building, Fuyuan Road, Xiangcheng District, Suzhou 215100, China
| | - Wenming Guo
- XCMG Earthmoving Machinery Division, NO. 99 Kunpeng Bei Road, Xuzhou Economic Development Zone, Xuzhou 221004, China
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14
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Kang R, Zhang P, Wei Z, Dong Z, Wang Y. Experimental Study on Ultrasonic Assisted Turning of GH4068 Superalloy. Materials (Basel) 2023; 16:ma16093554. [PMID: 37176436 PMCID: PMC10179904 DOI: 10.3390/ma16093554] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/30/2023] [Revised: 04/20/2023] [Accepted: 04/26/2023] [Indexed: 05/15/2023]
Abstract
GH4068 superalloy is a new type of nickel-based superalloy in the aerospace field. It is an important alloy material for the manufacture of aircraft tubular components and aero-engine hot-end components. These components need to be machined with good surface quality to meet their use requirements. New hybrid machining processes can improve the quality of surface finish compared to conventional machines. In this paper, ultrasonic assisted turning (UAT) technology was applied to the machining of GH4068 superalloy. The experimental system of UAT was established. Experiments of UAT and conventional turning (CT) of GH4068 superalloy were carried out to study the effects of cutting speed, feed speed, cutting depth and vibration amplitude on cutting force and surface roughness. The surface morphology of the workpiece and chip were observed. The experimental results show that Fx and Fy can be reduced by a maximum of 44% and 63%, respectively, and the surface roughness can be reduced by a maximum of 31% after adding ultrasonic vibration. Compared with CT, the UAT has a better machining quality, a more obvious chip-breaking effect, and a smaller chip bending radius, which guides the high-quality processing of the GH4068 superalloy.
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Affiliation(s)
- Renke Kang
- State Key Laboratory of High-Performance Precision Manufacturing, School of Mechanical Engineering, Dalian University of Technology, Dalian 116014, China
| | - Pengnan Zhang
- State Key Laboratory of High-Performance Precision Manufacturing, School of Mechanical Engineering, Dalian University of Technology, Dalian 116014, China
| | - Zhaocheng Wei
- State Key Laboratory of High-Performance Precision Manufacturing, School of Mechanical Engineering, Dalian University of Technology, Dalian 116014, China
| | - Zhigang Dong
- State Key Laboratory of High-Performance Precision Manufacturing, School of Mechanical Engineering, Dalian University of Technology, Dalian 116014, China
| | - Yidan Wang
- State Key Laboratory of High-Performance Precision Manufacturing, School of Mechanical Engineering, Dalian University of Technology, Dalian 116014, China
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15
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Song W, Zhang J, Xiao G, Yi M, Chen Z, Wang L, Chen J, Xu C. Accurate Cutting-Force Measurement with Smart Tool Holder in Lathe. Sensors (Basel) 2023; 23:s23094419. [PMID: 37177625 PMCID: PMC10181587 DOI: 10.3390/s23094419] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/03/2023] [Revised: 04/27/2023] [Accepted: 04/28/2023] [Indexed: 05/15/2023]
Abstract
Cutting force in lathe work is closely related to tool wear and affects the turning quality. Direct measurement of the cutting force by measuring the strain of the tool holder is challenging because the tool holder design aims to be highly rigid in order to undertake large cutting forces. Accordingly, the most popular dynamometer designs modify the standard tool holder by decreasing the structural rigidity of the holder, which reduces the machining precision and is not widely accepted. In order to solve the issue of the low stiffness of the dynamometer reducing the machining precision, in this paper, the ultra-low strain on the tool holder was successfully detected by the highly sensitive semiconductor strain gauges (SCSG) adjacent to the blade cutting insert. However, the cutting process would generate much heat, which increases the force measuring area temperature of the tool holder by about 30 °C. As a result, the readout drifted significantly with the temperature changes due to the high temperature coefficient of SCSG. To solve this problem, the temperature on the tool holder was monitored and a BP neural network was proposed to compensate for temperature drift errors. Our methods improved the sensitivity (1.14 × 10-2 mV/N) and the average relative error of the BP neural network prediction (≤1.48%) while maintaining the original stiffness of the tool holder. The smart tool holder developed possesses high natural frequency (≥6 kHz), it is very suitable for dynamic cutting-force measurement. The cutting experiment data in the lathe work show comparable performance with the traditional dynamometers and the resolution of the smart tool holder is 2 N (0.25% of total range).
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Affiliation(s)
- Wandong Song
- School of Mechanical Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan 250353, China
| | - Jingjie Zhang
- School of Mechanical Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan 250353, China
| | - Guangchun Xiao
- School of Mechanical Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan 250353, China
| | - Mingdong Yi
- School of Mechanical Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan 250353, China
| | - Zhaoqiang Chen
- School of Mechanical Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan 250353, China
| | - Li Wang
- School of Mechanical Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan 250353, China
| | - Jun Chen
- School of Mechanical Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan 250353, China
| | - Chonghai Xu
- School of Mechanical Engineering, Qilu University of Technology (Shandong Academy of Sciences), Jinan 250353, China
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16
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Płodzień M, Żyłka Ł, Stoić A. Modelling of the Face-Milling Process by Toroidal Cutter. Materials (Basel) 2023; 16:2829. [PMID: 37049123 PMCID: PMC10096468 DOI: 10.3390/ma16072829] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 03/08/2023] [Revised: 03/28/2023] [Accepted: 03/30/2023] [Indexed: 06/19/2023]
Abstract
When face milling using a toroidal cutter, with a change in the depth of the cut, the entering angle varies as well. An experimental test of the influence of cutting parameters, such as the depth of the cut and the feed per tooth on the cutting force components and surface roughness parameters, was conducted. The experimental test was carried out using a DMU 100 monoBLOCK CNC machine with registration of cutting force components and surface roughness parameters Ra, Rz, and RSm. FEM analysis of the face-milling process was also carried out and compared with the experimental results. The average deviation of the FEM values for cutting force components does not exceed 12%. Experimental models were established for each force component. It was shown that the depth of the cut has the strongest influence on each force component. The feed per tooth has a little impact on the cutting force. The obtained model of the feed force component is the most complex, and the model of the Fa component is only linear. The influence of the ap parameter on the surface roughness parameters is nonlinear and nonmonotonic. In the range of approx. ap = 2 mm, there is a maximum surface roughness.
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Affiliation(s)
- Marcin Płodzień
- Department of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, ul. W. Pola 2, 35-959 Rzeszow, Poland;
| | - Łukasz Żyłka
- Department of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, ul. W. Pola 2, 35-959 Rzeszow, Poland;
| | - Antun Stoić
- Mechanical Engineering Faculty, University of Slavonski Brod, Trg Ivane Brlic Mazuranic 2, 35000 Slavonski Brod, Croatia;
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17
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Zhang C, Zou D, Mazur M, Mo JPT, Li G, Ding S. The State of the Art in Machining Additively Manufactured Titanium Alloy Ti-6Al-4V. Materials (Basel) 2023; 16:2583. [PMID: 37048881 PMCID: PMC10095803 DOI: 10.3390/ma16072583] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 01/30/2023] [Revised: 03/16/2023] [Accepted: 03/17/2023] [Indexed: 06/19/2023]
Abstract
Titanium alloys are extensively used in various industries due to their excellent corrosion resistance and outstanding mechanical properties. However, titanium alloys are difficult to machine due to their low thermal conductivity and high chemical reactivity with tool materials. In recent years, there has been increasing interest in the use of titanium components produced by additive manufacturing (AM) for a range of high-value applications in aerospace, biomedical, and automotive industries. The machining of additively manufactured titanium alloys presents additional machining challenges as the alloys exhibit unique properties compared to their wrought counterparts, including increased anisotropy, strength, and hardness. The associated higher cutting forces, higher temperatures, accelerated tool wear, and decreased machinability lead to an expensive and unsustainable machining process. The challenges in machining additively manufactured titanium alloys are not comprehensively documented in the literature, and this paper aims to address this limitation. A review is presented on the machining characteristics of titanium alloys produced by different AM techniques, focusing on the effects of anisotropy, porosity, and post-processing treatment of additively manufactured Ti-6Al-4V, the most commonly used AM titanium alloy. The mechanisms resulting in different machining performance and quality are analysed, including the influence of a hybrid manufacturing approach combining AM with conventional methods. Based on the review of the latest developments, a future outlook for machining additively manufactured titanium alloys is presented.
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Affiliation(s)
- Chen Zhang
- School of Engineering, RMIT University, Melbourne, VIC 3083, Australia; (C.Z.); (M.M.); (J.P.T.M.)
| | - Dongyi Zou
- Faculty of Engineering and Information Technology, The University of Melbourne, Melbourne, VIC 3010, Australia;
| | - Maciej Mazur
- School of Engineering, RMIT University, Melbourne, VIC 3083, Australia; (C.Z.); (M.M.); (J.P.T.M.)
| | - John P. T. Mo
- School of Engineering, RMIT University, Melbourne, VIC 3083, Australia; (C.Z.); (M.M.); (J.P.T.M.)
| | - Guangxian Li
- College of Mechanical Engineering, Guangxi University, Nanning 530004, China
| | - Songlin Ding
- School of Engineering, RMIT University, Melbourne, VIC 3083, Australia; (C.Z.); (M.M.); (J.P.T.M.)
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18
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Pang S, Zhao W, Qiu T, Liu W, Yan P, Jiao L, Wang X. Effect of Cutting Fluid on Milled Surface Quality and Tool Life of Aluminum Alloy. Materials (Basel) 2023; 16:2198. [PMID: 36984078 PMCID: PMC10056421 DOI: 10.3390/ma16062198] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 02/07/2023] [Revised: 03/03/2023] [Accepted: 03/05/2023] [Indexed: 06/18/2023]
Abstract
The machining process of aluminum alloy usually produces built-up edge and tool sticking problems due to their low hardness and large plastic deformation, which may further affect the machined surface quality and tool life. This paper aims to investigate the influence of different cutting fluids on the machined surface quality and tool life during the milling process of 7050 aluminum alloy. A novel cutting fluid (QC-2803) was considered in the study, which is synthesized by addition of alkyl alcohol amide and chlorinated polyolefin, and the traditional cutting fluid (CCF-10) was used as the control group. The physical and chemical properties of two cutting fluids were characterized. The milling process of 7050 aluminum alloy was carried out under two different cutting fluid conditions. The machined surface morphology, cutting force and tool wear morphology were observed during the process. Results show that the surface tension of the novel cutting fluid is significantly lower than that of the traditional cutting fluid, which makes it easier to produce a lubricating film between the aluminum alloy and tool, and further benefits the machined surface quality and tool life. As a result, the surface roughness and cutting force are reduced by ~20.0% and ~42.9%, respectively, and the tool life is increased by 25.6% in the case of the novel cutting fluid (QC-2803). The results in this paper revealed the important laws of cutting fluid with metal surface quality, cutting performance and tool wear, which helps to control the machined surface quality and tool life by the selection of cutting fluid during metal milling.
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Affiliation(s)
- Shuoshuo Pang
- School of Mechanical Engineering, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing 100081, China
| | - Wenxiang Zhao
- Key Laboratory of Fundamental Science for Advanced Machining Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing 100081, China
| | - Tianyang Qiu
- Key Laboratory of Fundamental Science for Advanced Machining Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing 100081, China
| | - Weiliang Liu
- School of Mechanical Engineering, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing 100081, China
| | - Pei Yan
- Key Laboratory of Fundamental Science for Advanced Machining Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing 100081, China
| | - Li Jiao
- Key Laboratory of Fundamental Science for Advanced Machining Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing 100081, China
| | - Xibin Wang
- Key Laboratory of Fundamental Science for Advanced Machining Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing 100081, China
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19
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Zheng Z, Guo J, Gao R, Jin X. Research on the Cutting Force and Serrated Chips in Ultra-Precision Micro-Grooving of SLM Ti6Al4V Alloy. Micromachines (Basel) 2023; 14:533. [PMID: 36984940 PMCID: PMC10057032 DOI: 10.3390/mi14030533] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 01/29/2023] [Revised: 02/22/2023] [Accepted: 02/22/2023] [Indexed: 06/18/2023]
Abstract
Selective laser melting (SLM) has significant advantages in the near net shape manufacturing of metal parts with complex geometries. However, SLM parts usually have problems such as poor surface quality and low dimensional accuracy, which require post-processing. This paper focuses on the research around the influence of ultra-precision micro-grooving the SLM Ti6Al4V alloy on the cutting force and serrated chips. The influence of the processing parameters on the cutting force and surface processing quality was analyzed in detail, and the cutting simulation model of the SLM Ti6Al4V alloy was established. The formation process of the serrated chip was successfully simulated, and the experiments verified the reliability of the established model. The research results show that the dynamic cutting force and surface processing quality are mainly related to the depth of cut, and the two trends are consistent. It is also shown that the serrated chip begins on the free surface of the workpiece and propagates deeply in the shear zone, forming a shear band, and its serrated nodules move upward and forward to form periodic serrated chips.
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Affiliation(s)
- Zhongpeng Zheng
- Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China
- Department of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China
| | - Jiajing Guo
- Department of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China
| | - Ruilin Gao
- Department of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China
| | - Xin Jin
- Department of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China
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20
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Lai F, Hu A, Mao K, Wu Z, Lin Y. Effect of Milling Processing Parameters on the Surface Roughness and Tool Cutting Forces of T2 Pure Copper. Micromachines (Basel) 2023; 14:224. [PMID: 36677285 PMCID: PMC9863517 DOI: 10.3390/mi14010224] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/30/2022] [Revised: 01/05/2023] [Accepted: 01/12/2023] [Indexed: 06/17/2023]
Abstract
In this paper, the responses of machined surface roughness and milling tool cutting forces under the different milling processing parameters (cutting speed v, feed rate f, and axial cutting depth ap) are experimentally investigated to meet the increasing requirements for the mechanical machining of T2 pure copper. The effects of different milling processing parameters on cutting force and tool displacement acceleration are studied based on orthogonal and single-factor milling experiments. The three-dimensional morphologies of the workpieces are observed, and a white-light topography instrument measures the surface roughness. The results show that the degree of influence on Sa (surface arithmetic mean deviation) and Sq (surface root mean square deviation) from high to low level is the v, the f, and the ap. When v = 600 m/min, ap = 0.5 mm, f = 0.1 mm/r, Sa and Sq are 1.80 μm and 2.25 μm, respectively. The cutting forces in the three directions negatively correlate with increased cutting speed; when v = 600 m/min, Fx reaches its lowest value. In contrast, an increase in the feed rate and the axial cutting depth significantly increases Fx. The tool displacement acceleration amplitudes demonstrate a positive relationship. Variation of the tool displacement acceleration states leads to the different microstructure of the machined surfaces. Therefore, selecting the appropriate milling processing parameters has a positive effect on reducing the tool displacement acceleration, improving the machined surface quality of T2 pure copper, and extending the tool's life. The optimal milling processing parameters in this paper are the v = 600 m/min, ap = 0.5 mm, and f = 0.1 mm/r.
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21
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Reznicek M, Horava C, Ovsik M. Percentage Ratios of Cutting Forces during High-Reed Face Milling. Materials (Basel) 2022; 16:384. [PMID: 36614723 PMCID: PMC9821856 DOI: 10.3390/ma16010384] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/04/2022] [Revised: 12/12/2022] [Accepted: 12/27/2022] [Indexed: 06/17/2023]
Abstract
This research paper is concerned with the experimental study of high-feed end milling of 1.4541 (X6CrNiTi18-10) stainless steel with replaceable cermet plates. Several machining operations were performed under different cutting conditions. The variable values were depth of cut, feed per tooth and cutting speed. The results were analyzed, and cutting forces were evaluated for dependence on cutting conditions (cutting speed, depth of cut, feed per tooth). The obtained data were statistically processed and plotted in graphs. It was found that the percentage distribution of cutting forces changed as the tool load increased. The ratio of forces acting in individual axes also changed with varying trends. An increasing trend was recorded in the x and y axes, while a decreasing trend was recorded in the z axis. Measured change, approximately 10%, can no longer be neglected as it can significantly influence the clamping stability of a part.
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22
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Biruk-Urban K, Bere P, Józwik J, Leleń M. Experimental Study and Artificial Neural Network Simulation of Cutting Forces and Delamination Analysis in GFRP Drilling. Materials (Basel) 2022; 15:ma15238597. [PMID: 36500093 PMCID: PMC9738306 DOI: 10.3390/ma15238597] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/03/2022] [Revised: 11/27/2022] [Accepted: 11/28/2022] [Indexed: 05/27/2023]
Abstract
This paper reports the results of measurements of cutting forces and delamination in drilling of Glass-Fiber-Reinforced Polymer (GFRP) composites. Four different types of GFRP composites were tested, made by a different manufacturing method and had a different fiber type, weight fraction (wf) ratio, number of layers, but the same stacking sequence. GFRP samples were made using two technologies: a novel method based on the use of a specially designed pressing device and hand lay-up and vacuum bag technology process. The study was conducted with variable technological parameters: cutting speed vc and feed per tooth fz. The two-edge carbide diamond-coated drill produced by Seco Company was used in the experiments. Cutting-force components and delamination factor were measured in the experiments, and photos of the holes were taken to determine the delamination. In addition, modeling of cause-and-effect relationships between the technological drilling parameters vc and fz was simulated with the use of artificial neural network modeling. For all tested GFRP materials, an increase in fz led to an increase in the amplitude of cutting-force component Fz. The lowest values of the amplitude of cutting-force component Fz were obtained with the lowest tested feed per tooth value of 0.04 mm/tooth for all tested materials. It was observed that materials produced with the use of the specially designed pressing device were characterized by lower values of the cutting-force component Fz. It was also found that the delamination factor increased with an increase in fz for all tested GFRP materials. A comparison of the lowest and the highest values of fz revealed that the lowest delamination factor increase was archived by the B1 material and amounted to about 12.5%. The error margin of the obtained numerical modeling results does not exceed 15%, so it can be concluded that artificial neural networks are a suitable tool for modeling cutting force amplitudes as a function of vc and fz. The study has shown that the use of the special pressing device during the manufacturing of composite materials has a positive effect on delamination.
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Affiliation(s)
- Katarzyna Biruk-Urban
- Department of Production Engineering, Mechanical Engineering Faculty, Lublin University of Technology, 20-618 Lublin, Poland
| | - Paul Bere
- Department of Manufacturing Engineering, Faculty of Industrial Engineering, Robotics and Production Management, Technical University of Cluj-Napoca, Memorandumului 28, 400114 Cluj-Napoca, Romania
| | - Jerzy Józwik
- Department of Production Engineering, Mechanical Engineering Faculty, Lublin University of Technology, 20-618 Lublin, Poland
| | - Michał Leleń
- Department of Production Engineering, Mechanical Engineering Faculty, Lublin University of Technology, 20-618 Lublin, Poland
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23
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Lei H, Cheng J, Yang D, Zhao L, Chen M, Wang J, Liu Q, Ding W, Chen G. Effect of Pre-Existing Micro-Defects on Cutting Force and Machined Surface Quality Involved in the Ball-End Milling Repairing of Flawed KDP Crystal Surfaces. Materials (Basel) 2022; 15:7407. [PMID: 36362999 PMCID: PMC9654360 DOI: 10.3390/ma15217407] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 09/11/2022] [Revised: 10/18/2022] [Accepted: 10/20/2022] [Indexed: 06/16/2023]
Abstract
When serving in extremely high-power laser conditions, KH2PO4 (KDP) surfaces are susceptible to incur laser damage points (also known as defects). Using micro-ball end milling cutters to repair and remove the pre-existing damage points on the flawed KDP crystal surface is the most effective method to control the growth of laser damage points on KDP crystal surfaces and prolong their service life. However, there are various forms of micro-defects (such as pits, scratches and brittle fractures) around the laser damage points on KDP crystal surfaces which possess remarkable effects on the micro-milling repair process and consequently deteriorate the repair quality. In this work, combined with nano-indentation experiments, elastic-plastic mechanics and fracture mechanics theory, a constitutive model considering the anisotropic property of KDP crystals and a three-dimensional (3D) finite element model (FEM) were established to simulate the cutting force and surface topography involved in the ball-end milling repairing of flawed KDP crystal surfaces. Besides, the micro-milling experiments were conducted to evaluate the change of cutting force and machined surface quality in the presence of micro-defects with various feed rates. The results show that micro-defects would induce the fluctuation of cutting force and a change of the undeformed cutting thickness (UCT) in the process of repairing the damage points on the crystal surface, which would lead to the brittle-ductile transition (BDT) and affect the machined surface quality. The machined surface quality was found to be deteriorated by the pre-existing micro-defects when the UCT was small (the UCT was less than 375 nm). On the contrary, brittle mode cutting in the local area can be transformed into ductile mode cutting, resulting in an improvement of repaired surface quality that is exhibited by the cutting force and microtopography. This work has great theoretical significance and engineering practical value for the promotion and application of micro-milling repairing technology in the practical manufacturing and operation of KDP optics applied to high-power laser systems.
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Affiliation(s)
- Hongqin Lei
- State Key Laboratory of Robotics and System, Harbin Institute of Technology, Harbin 150001, China
- School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China
| | - Jian Cheng
- State Key Laboratory of Robotics and System, Harbin Institute of Technology, Harbin 150001, China
- School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China
| | - Dinghuai Yang
- School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China
| | - Linjie Zhao
- School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China
| | - Mingjun Chen
- State Key Laboratory of Robotics and System, Harbin Institute of Technology, Harbin 150001, China
- School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China
| | - Jinghe Wang
- School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China
| | - Qi Liu
- School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China
| | - Wenyu Ding
- School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China
| | - Guang Chen
- School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China
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24
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Gao S, Duan X, Zhu K, Zhang Y. Generic Cutting Force Modeling with Comprehensively Considering Tool Edge Radius, Tool Flank Wear and Tool Runout in Micro-End Milling. Micromachines (Basel) 2022; 13:1805. [PMID: 36363826 PMCID: PMC9697499 DOI: 10.3390/mi13111805] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 09/28/2022] [Revised: 10/18/2022] [Accepted: 10/18/2022] [Indexed: 06/16/2023]
Abstract
Accurate cutting force prediction is crucial in improving machining precision and surface quality in the micro-milling process, in which tool wear and runout are essential factors. A generic analytic cutting force model considering the effect of tool edge radius on tool flank wear and tool runout in the micro-end milling process is proposed. Based on the analytic modeling of the cutting part of the cutting edge in the end face of the micro-end mill bottom, the actual radius model of the worn tool is established, considering the tool edge radius and tool flank wear. The tool edge radius, tool wear, tool runout, trochoidal trajectories of the current cutting edge, and all cutting edges in the previous cycle are comprehensively considered in the instantaneous uncut chip thickness calculation and the cutter-workpiece engagement determination. The cutting force coefficient model including tool wear is established. A series of milling experiments are performed to verify the accuracy and effectiveness of the proposed cutting force model. The results show that the predicted cutting forces are in good agreement with the experimental cutting forces, and it is necessary to consider tool wear in the micro-milling force modeling. The results indicate that tool wear has a significant influence on the cutting forces and cutting force coefficients in the three directions, and the influences of tool wear on the axial cutting force and axial force coefficient are the largest, respectively. The proposed cutting force model can contribute to real-time machining process monitoring, cutting parameters optimization and ensuring machining quality.
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Affiliation(s)
- Shuaishuai Gao
- School of Mathematics and Statistics, Central China Normal University, Wuhan 430079, China
| | - Xianyin Duan
- Key Laboratory of Metallurgical Equipment and Control Technology, Ministry of Education, Wuhan University of Science and Technology, Wuhan 430081, China
| | - Kunpeng Zhu
- Institute of Intelligent Machines, Hefei Institutes of Physical Science, Chinese Academy of Sciences, Hefei 230031, China
| | - Yu Zhang
- Key Laboratory of Metallurgical Equipment and Control Technology, Ministry of Education, Wuhan University of Science and Technology, Wuhan 430081, China
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Zawadzki P, Talar R, Patalas A, Legutko S. Influence of Machining Parameters on Cutting and Chip-Formation Process during Cortical Bone Orthogonal Machining. Materials (Basel) 2022; 15:ma15186414. [PMID: 36143728 PMCID: PMC9502497 DOI: 10.3390/ma15186414] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/04/2022] [Revised: 09/06/2022] [Accepted: 09/10/2022] [Indexed: 05/08/2023]
Abstract
Cortical bone machining is commonly used in craniofacial surgery. The shaping of bone surfaces requires a precise determination of the process’s complexity due to the cutting tool’s defined or undefined geometry. Therefore, research was carried out to assess the impact of the rake angle (γ), clearance angle and depth of cut (d) on the cortical bone machining process. Analysis was carried out based on the orthogonal cutting in three directions. The cutting tool shape was simplified, and the cutting forces and the chip-formation process were monitored. The highest values of the resultant cutting force and shear force were recorded for γ < 0. The specific cutting force decreases with the increase of d. Cutting in the transverse direction is characterized by the highest values of resultant cutting force and shear force. The coefficient of friction depends primarily on the d and takes a constant value or increases with the increase of γ. The tests showed that the chips are formed in the entire range of d ≥ 0.5 µm and create regular shapes for d ≥ 10 µm. The research novelty confirms that even negative cutting angles guarantee controlled cutting and can find wider application in surgical procedures.
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Li S, Han J, Yu H, Wang J, Lu M, Tian Y, Lin J. Finite Element Investigation on Cutting Force and Residual Stress in 3D Elliptical Vibration Cutting Ti6Al4V. Micromachines (Basel) 2022; 13:mi13081278. [PMID: 36014200 PMCID: PMC9412402 DOI: 10.3390/mi13081278] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/27/2022] [Revised: 08/05/2022] [Accepted: 08/06/2022] [Indexed: 05/04/2023]
Abstract
Titanium alloy is a typical difficult-to-machine material with features of superhigh strength and hardness, and low elastic modulus. It is difficult to guarantee the processing quality and efficiency due to the high cutting force and tool wear in conventional cutting. Elliptical vibration cutting (EVC) as an effective method can improve the machinability of titanium alloys. In this paper, the finite element method (FEM) was adopted to study the cutting force and residual stress of 3D EVC in machining of Ti6Al4V. The Johnson-Cook constitutive model was utilized to illustrate the plastic behavior of Ti6Al4V alloy. The kinematics of the 3D EVC was described, and then the influence of various cutting speeds, vibration amplitudes, vibration frequencies and depths of cut on cutting force and residual stress were carried out and analyzed. The simulation results show that the cutting speed, vibration amplitude a, vibration frequency and depth of cut have larger effect on principal force. In addition, the compressive stress layer can be easily obtained near the machined surface by using 3D EVC, which is helpful to improve the working performance of workpiece.
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Affiliation(s)
- Shiyu Li
- School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China
| | - Jinguo Han
- School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China
- Shandong Provincial Key Laboratory of Precision Manufacturing and Non-Traditional Machining, Shandong University of Technology, Zibo 255049, China
- Correspondence:
| | - Haiqiang Yu
- School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China
| | - Jinhui Wang
- School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China
| | - Mingming Lu
- School of Mechatronic Engineering, Changchun University of Technology, Changchun 130012, China
| | - Yebing Tian
- School of Mechanical Engineering, Shandong University of Technology, Zibo 255049, China
| | - Jieqiong Lin
- School of Mechatronic Engineering, Changchun University of Technology, Changchun 130012, China
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Liu T, Wang Q, Wang W. Micro-Milling Tool Wear Monitoring via Nonlinear Cutting Force Model. Micromachines (Basel) 2022; 13:943. [PMID: 35744558 DOI: 10.3390/mi13060943] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/09/2022] [Revised: 06/06/2022] [Accepted: 06/10/2022] [Indexed: 11/18/2022]
Abstract
Mechanistic cutting force model has the potential for monitoring micro-milling tool wear. However, the existing studies mainly consider the linear cutting force model, and they are incompetent to monitor the micro-milling tool wear which has a significant nonlinear effect on the cutting force due to the cutting-edge radius size effect. In this study, a nonlinear mechanistic cutting force model considering the comprehensive effect of cutting-edge radius and tool wear on the micro-milling force is constructed for micro-milling tool wear monitoring. A stepwise offline optimization approach is proposed to estimate the multiple parameters of the model. By minimizing the gap between the theoretical force expressed by the nonlinear model and the force measured in real-time, the tool wear condition is online monitored. Experiments show that, compared with the linear model, the nonlinear model has significantly improved cutting force prediction accuracy and tool wear monitoring accuracy.
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Ning H, Zheng H, Wang G. Establishment of Analytical Model for CFRP Cutting Force Considering the Radius of the Edge Circle. Materials (Basel) 2022; 15:2127. [PMID: 35329582 DOI: 10.3390/ma15062127] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/01/2022] [Revised: 03/10/2022] [Accepted: 03/11/2022] [Indexed: 01/27/2023]
Abstract
Carbon fiber-reinforced composite material (CFRP) has been widely applied in the aerospace industry, which places demanding requirements on the accuracy and quality of its processing. However, there remains a lack of clarity on the microscopic material removal process of CFRP, despite substantial relevant research. This paper aims to reveal the mechanism of material removal in the CFRP cutting process at different fiber cutting angles and to establish an analytical model for CFRP cutting force by considering the radius of the edge circle. Furthermore, the CFRP cutting force analytical model was established by considering the radius of the edge circle on the basis of the CFRP representative volume unit (RVE). According to the model, the cutting process was divided into three regions, the cutting slip zone, fiber fracture zone, and spring back zone, with consideration given to the effect of residual fibers on the cutter teeth. The CFRP cutting finite element model was defined using the software Abaqus, while the chip removal and single-fiber deformation processes were analyzed using the finite element model. As indicated by the experimental results, the analytical model is reliable and capable of providing cutting force values within a 15% deviation.
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Czán A, Joch R, Šajgalík M, Holubják J, Horák A, Timko P, Valíček J, Kušnerová M, Harničárová M. Experimental Study and Verification of New Monolithic Rotary Cutting Tool for an Active Driven Rotation Machining. Materials (Basel) 2022; 15:ma15051630. [PMID: 35268861 PMCID: PMC8911487 DOI: 10.3390/ma15051630] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/30/2021] [Revised: 02/15/2022] [Accepted: 02/18/2022] [Indexed: 02/05/2023]
Abstract
Forced rotation turning appears to be an effective machining method due to higher tool life, time efficiency and acceptable quality. Several studies have been carried out to investigate the basic characteristics of forced rotation machining. So far, tools are used whose design included several components. However, such tools may generate vibrations, which are undesirable in the process. In engineering practice, most vibration problems are solved by reducing the cutting parameters (cutting speed and feed rate), which reduces machining productivity. For this reason, a new type of monolithic rotary tool has been designed that eliminates the design complexity and high assembly accuracy requirements of current rotary tools. Based on the performed experimental research, it is possible to define the influence of cutting parameters on the cutting force. Next, the equation of the cutting force and the resulting roughness of the machined surface was determined. In the introduction, the results of the analysis of machining parameters with a rotary tool were added. The presented solution fundamentally validates the new monolithic tool for forced rotation technology and defines its application for different machining materials.
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Affiliation(s)
- Andrej Czán
- Department of Machining and Manufacturing Technology, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 010 26 Žilina, Slovakia; (A.C.); (R.J.); (M.Š.); (J.H.); (A.H.); (P.T.); (J.V.)
| | - Richard Joch
- Department of Machining and Manufacturing Technology, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 010 26 Žilina, Slovakia; (A.C.); (R.J.); (M.Š.); (J.H.); (A.H.); (P.T.); (J.V.)
| | - Michal Šajgalík
- Department of Machining and Manufacturing Technology, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 010 26 Žilina, Slovakia; (A.C.); (R.J.); (M.Š.); (J.H.); (A.H.); (P.T.); (J.V.)
| | - Jozef Holubják
- Department of Machining and Manufacturing Technology, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 010 26 Žilina, Slovakia; (A.C.); (R.J.); (M.Š.); (J.H.); (A.H.); (P.T.); (J.V.)
| | - Andrej Horák
- Department of Machining and Manufacturing Technology, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 010 26 Žilina, Slovakia; (A.C.); (R.J.); (M.Š.); (J.H.); (A.H.); (P.T.); (J.V.)
| | - Pavol Timko
- Department of Machining and Manufacturing Technology, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 010 26 Žilina, Slovakia; (A.C.); (R.J.); (M.Š.); (J.H.); (A.H.); (P.T.); (J.V.)
| | - Jan Valíček
- Department of Machining and Manufacturing Technology, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 010 26 Žilina, Slovakia; (A.C.); (R.J.); (M.Š.); (J.H.); (A.H.); (P.T.); (J.V.)
- Department of Mechanical Engineering, Faculty of Technology, Institute of Technology and Business in České Budějovice, Okružní 10, 370 01 České Budějovice, Czech Republic;
| | - Milena Kušnerová
- Department of Mechanical Engineering, Faculty of Technology, Institute of Technology and Business in České Budějovice, Okružní 10, 370 01 České Budějovice, Czech Republic;
| | - Marta Harničárová
- Department of Machining and Manufacturing Technology, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 010 26 Žilina, Slovakia; (A.C.); (R.J.); (M.Š.); (J.H.); (A.H.); (P.T.); (J.V.)
- Department of Mechanical Engineering, Faculty of Technology, Institute of Technology and Business in České Budějovice, Okružní 10, 370 01 České Budějovice, Czech Republic;
- Correspondence:
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Kovalčík J, Mašek P, Malý J, Kožmín P, Syrovátka J. The Effect of Coatings on Cutting Force in Turning of C45 Steel. Materials (Basel) 2022; 15:590. [PMID: 35057307 DOI: 10.3390/ma15020590] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/21/2021] [Revised: 01/06/2022] [Accepted: 01/08/2022] [Indexed: 02/01/2023]
Abstract
This article focuses on the development of a mathematical model of a cutting force that is applicable for coated and uncoated cutting tool inserts and aims to enable more accurate calculation of the cutting force. Two common PVD coatings, AlTiN and TiAlCrN, were used. Firstly, a mathematical model of the cutting force based on the specific cutting force and cutting area is proposed. This mathematical model considers the cutting speed and coating correction factor as well as the real cutting edge geometry, i.e., it includes both the straight and rounded parts of the cutting edge. For this proposed model, material constants for C45 steel, which was machined with uncoated inserts, were obtained. Before determining an equation for a coating correction factor and implementing it into the model, experimental cutting force data for coated and uncoated inserts were compared using a paired t-test. The result was that the difference between them was statistically significant. Their percentage difference was found to be up to 4%. The correction factor equation that was obtained and implemented into the mathematical model was applied to compare the calculated and experimental data of the coated inserts, also using a paired t-test. The result was that the difference between them was insignificant. Moreover, their percentage difference was found to be up to 0.6%.
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31
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Yang B, Wang H, Fu K, Wang C. Prediction of Cutting Force and Chip Formation from the True Stress-Strain Relation Using an Explicit FEM for Polymer Machining. Polymers (Basel) 2022; 14:189. [PMID: 35012211 DOI: 10.3390/polym14010189] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/25/2021] [Revised: 11/23/2021] [Accepted: 11/24/2021] [Indexed: 11/17/2022] Open
Abstract
In the present work, an explicit finite element (FE) model was developed for predicting cutting forces and chip morphologies of polymers from the true stress–strain curve. A dual fracture process was used to simulate the cutting chip formation, incorporating both the shear damage failure criterion and the yield failure criterion, and considering the strain rate effect based on the Johnson–Cook formulation. The frictional behaviour between the cutting tool and specimen was defined by Coulomb’s law. Further, the estimated cutting forces and chip thicknesses at different nominal cutting depths were utilized to determine the fracture toughness of the polymer, using an existing mechanics method. It was found that the fracture toughness, cutting forces, and chip morphologies predicted by the FE model were consistent with the experimental results, which proved that the present FE model could effectively reflect the cutting process. In addition, a parametrical analysis was performed to investigate the effects of cutting depth, rake angle, and friction coefficient on the cutting force and chip formation, which found that, among these parameters, the friction coefficient had the greatest effect on cutting force.
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32
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Lu Z, Wang H, Zeng Q, Wang Z, Wan L, Li C. Research on Cutting Performance of Conical Pick Cutting Rock Plate with One Side Constrain and Three Sides Free. Sci Prog 2022; 105:368504221079191. [PMID: 35188834 PMCID: PMC10450335 DOI: 10.1177/00368504221079191] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 08/28/2023]
Abstract
To improve the conical pick cutting performance by per cutting to the free surface. The cutting performance of rock and rock plate breaking are investigated by theoretical and experimental methods. Analyzed the fracture position of the rock plate with constrained one side by the pick to study the effect of rock properties and the rock plate structural parameters on cutting force. The results indicated that the rock plate fracture is mainly from the constrained side and center of the rock plate. The cutting force of the conical pick is significantly affected by the rock plate structural parameters and the constraint sides of the rock plate number. The cutting force increases obviously with the increase of plate thickness, cutting point depth, and the rock uniaxial compressive strength. However, the influence of rock plate constrains sides number is opposite. It provides a basis for improving the cutting performance of pick and predicting the rock plate fracture.
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Affiliation(s)
- Zhenguo Lu
- College of Transportation, Shandong University of Science and Technology, Qingdao, China
| | - Hongbin Wang
- College of Transportation, Shandong University of Science and Technology, Qingdao, China
| | - Qingliang Zeng
- College of Transportation, Shandong University of Science and Technology, Qingdao, China
- College of Information Science and Engineering, Shandong Normal University, Jinan, China
| | - Zhiwen Wang
- College of Mechanical and Electronic Engineering, Shandong University of Science and Technology, Qingdao, China
| | - Lirong Wan
- College of Mechanical and Electronic Engineering, Shandong University of Science and Technology, Qingdao, China
| | - Changjiang Li
- College of Transportation, Shandong University of Science and Technology, Qingdao, China
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Liu T, Zhang K, Wang G, Wang C. Prediction of Nonlinear Micro-Milling Force with a Novel Minimum Uncut Chip Thickness Model. Micromachines (Basel) 2021; 12:1495. [PMID: 34945345 DOI: 10.3390/mi12121495] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/08/2021] [Revised: 11/27/2021] [Accepted: 11/28/2021] [Indexed: 11/17/2022]
Abstract
The minimum uncut chip thickness (MUCT), dividing the cutting zone into the shear region and the ploughing region, has a strong nonlinear effect on the cutting force of micro-milling. Determining the MUCT value is fundamental in order to predict the micro-milling force. In this study, based on the assumption that the normal shear force and the normal ploughing force are equivalent at the MUCT point, a novel analytical MUCT model considering the comprehensive effect of shear stress, friction angle, ploughing coefficient and cutting-edge radius is constructed to determine the MUCT. Nonlinear piecewise cutting force coefficient functions with the novel MUCT as the break point are constructed to represent the distribution of the shear/ploughing force under the effect of the minimum uncut chip thickness. By integrating the cutting force coefficient function, the nonlinear micro-milling force is predicted. Theoretical analysis shows that the nonlinear cutting force coefficient function embedded with the novel MUCT is absolutely integrable, making the micro-milling force model more stable and accurate than the conventional models. Moreover, by considering different factors in the MUCT model, the proposed micro-milling force model is more flexible than the traditional models. Micro-milling experiments under different cutting conditions have verified the efficiency and improvement of the proposed micro-milling force model.
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Su Y, Li L. An Investigation of Cutting Performance and Action Mechanism in Ultrasonic Vibration-Assisted Milling of Ti6Al4V Using a PCD Tool. Micromachines (Basel) 2021; 12:mi12111319. [PMID: 34832731 PMCID: PMC8622777 DOI: 10.3390/mi12111319] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/05/2021] [Revised: 10/18/2021] [Accepted: 10/21/2021] [Indexed: 11/25/2022]
Abstract
A polycrystalline diamond (PCD) tool is employed in cutting various titanium alloys because of its excellent properties. However, improving the cutting performance of titanium alloys is still a challenge. Here, an experimental investigation on the influence of ultrasonic vibration-assisted machining (UVAM) of Ti6Al4V titanium alloy on the cutting performance and action mechanism was studied using a PCD tool. Cutting force, machined surface, surface adhesion, and wear morphology were analyzed. The results indicated that UVAM can effectively improve cutting performance. It was found that there was serious adhesion and wear of slight fragments close to the cutting edge after ultrasonic-assisted dry milling. Furthermore, the action mechanism of UVAM in improving cutting performance was discussed and analyzed from the perspective of intermittent cutting.
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Affiliation(s)
- Yongsheng Su
- School of Mechanical Engineering, Anhui Polytechnic University, Wuhu 241000, China
- Correspondence:
| | - Liang Li
- College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics & Astronautics, Nanjing 210016, China;
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35
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Hlásková L, Procházka J, Novák V, Čermák P, Kopecký Z. Interaction between Thermal Modification Temperature of Spruce Wood and the Cutting and Fracture Parameters. Materials (Basel) 2021; 14:ma14206218. [PMID: 34683809 PMCID: PMC8539808 DOI: 10.3390/ma14206218] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/18/2021] [Revised: 10/11/2021] [Accepted: 10/13/2021] [Indexed: 11/16/2022]
Abstract
This work examines the effect of thermal modification temperatures in the production of thermally modified wood on the cutting and fracture parameters when cutting heat-treated spruce wood by a circular sawblade machine. The samples were thermally modified at 160, 180, 200, and 220 °C. One sample was unmodified and was used as a reference sample. On the basis of the performed experiments, the fracture parameters (fracture toughness and shear yield strength) were calculated for the axial–perpendicular direction of cutting. In comparison with the theoretical assumptions, the influence of temperature on the cutting and fracture parameters was confirmed. Thermally treated wood is characterized by increased fragility and susceptibility to crack formation, as well as reduced density, bending strength, and shear strength. These properties significantly affect the size of the cutting force and feed force, as well as the fracture parameters. As the temperature increases, the values of these parameters decrease. The mentioned material characteristics could be useful for the optimization of the cutting process, as well as for the issue of energy consumption during the machining of heat-treated wood.
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Abstract
The conical pick is the most crucial tool of roadheader for breaking rock, establishing the conical pick cutting rock and conical pick fatigue life numerical simulation models to investigate the influence of cutting parameters on rock damage, average peak cutting force, specific cutting energy and the conical pick fatigue life. The research results indicate that the width and depth of rock damage increase with increasing cutting depth and cutting speed. The average peak cutting force and the specific cutting energy have the same changing tendency. The changing trend of conical pick fatigue life and conical pick stress is opposite relationship. The optimum cutting angle of the conical pick cutting rock is 45°. Applying the research results for guiding the optimization of the cutting parameters reduces the specific cutting energy and stress and improves the conical pick fatigue life.
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Affiliation(s)
- Qingliang Zeng
- College of Mechanical and Electronic
Engineering, Shandong University of Science and
Technology, Qingdao, China
- Shandong Normal University, Jinan,
China
| | - Zhiwen Wang
- College of Mechanical and Electronic
Engineering, Shandong University of Science and
Technology, Qingdao, China
| | - Zhenguo Lu
- College of Transportation, Shandong University of Science and
Technology, Qingdao, China
| | - Lirong Wan
- College of Mechanical and Electronic
Engineering, Shandong University of Science and
Technology, Qingdao, China
| | - Zhihai Liu
- College of Transportation, Shandong University of Science and
Technology, Qingdao, China
| | - Xin Zhang
- College of Mechanical and Electronic
Engineering, Shandong University of Science and
Technology, Qingdao, China
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37
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Platt T, Meijer A, Merhofe T, Biermann D. Simulation-Based and Experimental Investigation of Micro End Mills with Wiper Geometry. Micromachines (Basel) 2021; 12:496. [PMID: 33925603 DOI: 10.3390/mi12050496] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/01/2021] [Revised: 04/14/2021] [Accepted: 04/23/2021] [Indexed: 11/17/2022]
Abstract
One of the major advantages of micromachining is the high achievable surface quality at highly flexible capabilities in terms of the machining of workpieces with complex geometric properties. Unfortunately, finishing operations often result in extensive process times due to the dependency of the resulting surface topography on the cutting parameter, e.g., the feed per tooth, fz. To overcome this dependency, special tool shapes, called wipers, have proven themselves in the field of turning. This paper presents the transfer of such tool shapes to solid carbide milling tools for micromachining. In this context, a material removal simulation (MRS) was used to investigate promising wiper geometries for micro end mills (d = 1 mm). Through experimental validation of the results, the surface topography, the resulting process forces, and tendencies in the residual stress state were investigated, machining the hot work tool steel (AISI H11). The surface-related results show a high agreement and thus the potential of MRS for tool development. Deviations from the experimental data for large wipers could be attributed to the non-modeled tool deflections, friction, and plastic deformations. Furthermore, a slight geometry-dependent increase in cutting forces and compressive stresses were observed, while a significant reduction in roughness up to 84% and favorable topography conditions were achieved by adjusting wipers and cutting parameters.
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38
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Pałubicki B. Cutting Forces in Peripheral Up-Milling of Particleboard. Materials (Basel) 2021; 14:2208. [PMID: 33923057 DOI: 10.3390/ma14092208] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/04/2021] [Revised: 04/21/2021] [Accepted: 04/22/2021] [Indexed: 11/17/2022]
Abstract
An analysis of forces acting in the peripheral up-milling of particleboard is presented. First, a novel method of high-frequency piezoelectric force signal treatment is proposed and used to separate the original force signal from the vibrations of the previous cutting iteration. This allows for the analysis of single chip cutting force courses during industrial CNC (Computer Numerical Control) milling. The acting forces are compared with the theoretical, instantaneous, uncut chip thickness. The results show that, for a range of 40-60 m/s, the higher the cutting speed used, the higher the resultant and principal cutting forces. The method of cutting thrust force used was similar to that observed in solid wood milling, i.e., first using a pushing action, followed by a pulling action. The obtained average specific principal cutting forces for particleboard peripheral up-milling are equal to 32.0 N/mm2 for slow and 37.6 N/mm2 for fast milling. The specific cutting thrust force decreases with the increase in instantaneous uncut chip thickness.
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Płodzień M, Żyłka Ł, Sułkowicz P, Żak K, Wojciechowski S. High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude. Materials (Basel) 2021; 14:ma14092196. [PMID: 33922909 PMCID: PMC8123177 DOI: 10.3390/ma14092196] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/13/2021] [Revised: 04/21/2021] [Accepted: 04/23/2021] [Indexed: 11/25/2022]
Abstract
High feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the high feed milling (HFM), experimental tests were conducted, preceded by an analysis of cutting zones when milling with an HF face cutter. The face milling tests of 42CrMo4 steel with the use of an HF cutter characterized by an entering angle, dependent on axial depth of cut ap and insert radius r values, as well as with a conventional face cutter with the entering angle of 45° were performed. The study focused on analyzing the vibration amplitude, cutting force components in the workpiece coordinate system, and surface roughness. The experimental tests proved, that when milling with constant cut layer thickness, the high feed cutter allowed to obtain twice the cutting volume in comparison with the conventional face cutter. However, higher machining efficiency resulted in an increase in cutting force components. Furthermore, the results indicate significantly higher surface roughness and higher vibration amplitudes when milling with the HF cutter.
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Affiliation(s)
- Marcin Płodzień
- Department of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, ul. W. Pola 2, 35-959 Rzeszow, Poland; (M.P.); (Ł.Ż.); (P.S.)
| | - Łukasz Żyłka
- Department of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, ul. W. Pola 2, 35-959 Rzeszow, Poland; (M.P.); (Ł.Ż.); (P.S.)
| | - Paweł Sułkowicz
- Department of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, ul. W. Pola 2, 35-959 Rzeszow, Poland; (M.P.); (Ł.Ż.); (P.S.)
| | - Krzysztof Żak
- Department of Manufacturing and Materials Engineering, The Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758 Opole, Poland;
| | - Szymon Wojciechowski
- Institute of Mechanical Technology, The Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland
- Correspondence:
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Elgnemi TSM, Jun MBG, Songmene V, Samuel AM. Milling Performance of CFRP Composite and Atomised Vegetable Oil as a Function of Fiber Orientation. Materials (Basel) 2021; 14:ma14082062. [PMID: 33923912 PMCID: PMC8073150 DOI: 10.3390/ma14082062] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/30/2021] [Revised: 04/13/2021] [Accepted: 04/17/2021] [Indexed: 01/09/2023]
Abstract
Carbon fiber reinforced polymers (CFRPs) have found diverse applications in the automotive, space engineering, sporting goods, medical and military sectors. CFRP parts require limited machining such as detouring, milling and drilling to produce the shapes used, or for assembly purposes. Problems encountered while machining CFRP include poor tool performance, dust emission, poor part edge quality and delamination. The use of oil-based metalworking fluid could help improve the machining performance for this composite, but the resulting humidity would deteriorate the structural integrity of the parts. In this work the performance of an oil-in-water emulsion, obtained using ultrasonic atomization but no surfactant, is examined during the milling of CFRP in terms of fiber orientation and milling feed rate. The performance of wet milling is compared with that of a dry milling process. The tool displacement-fiber orientation angles (TFOA) tested are 0°, 30°, 45°, 60°, and 90°. The output responses analyzed were cutting force, delamination, and tool wear. Using atomized vegetable oil helps in significantly reducing the cutting force, tool wear, and fiber delamination as compared to the dry milling condition. The machining performance was also strongly influenced by fiber orientation. The interactions between the fiber orientation, the machining parameters and the tested vegetable oil-based fluid could help in selecting appropriate cutting parameters and thus improve the machined part quality and productivity.
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Affiliation(s)
- Tarek-Shaban-Mohamed Elgnemi
- Department of Mechanical Engineering, École de Technologie Supérieure (ÉTS), Montreal, QC H3C 1K3, Canada; (T.-S.-M.E.); (A.M.S.)
| | - Martin Byung-Guk Jun
- Department of Mechanical Engineering, Purdue University, West Lafayette, IN 47907, USA;
| | - Victor Songmene
- Department of Mechanical Engineering, École de Technologie Supérieure (ÉTS), Montreal, QC H3C 1K3, Canada; (T.-S.-M.E.); (A.M.S.)
- Correspondence:
| | - Agnes Marie Samuel
- Department of Mechanical Engineering, École de Technologie Supérieure (ÉTS), Montreal, QC H3C 1K3, Canada; (T.-S.-M.E.); (A.M.S.)
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Zhang L, Sha X, Liu M, Wang L, Pang Y. Cutting Force Prediction Models by FEA and RSM When Machining X56 Steel with Single Diamond Grit. Micromachines (Basel) 2021; 12:326. [PMID: 33808702 DOI: 10.3390/mi12030326] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/01/2021] [Revised: 03/14/2021] [Accepted: 03/15/2021] [Indexed: 11/25/2022]
Abstract
In the field of underwater emergency maintenance, submarine pipeline cutting is generally performed by a diamond wire saw. The process, in essence, involves diamond grits distributed on the surface of the beads cutting X56 pipeline steel bit by bit at high speed. To find the effect of the different parameters (cutting speed, coefficient of friction and depth of cut) on cutting force, the finite element (FEA) method and response surface method (RSM) were adopted to obtain cutting force prediction models. The former was based on 64 simulations; the latter was designed according to DoE (Design of Experiments). Confirmation experiments were executed to validate the regression models. The results indicate that most of the prediction errors were within 10%, which were acceptable in engineering. Based on variance analyses of the RSM models, it could be concluded that the depth of the cut played the most important role in determining the cutting force and coefficient the of friction was less influential. Despite making little direct contribution to the cutting force, the cutting speed is not supposed to be high for reducing the coefficient of friction. The cutting force models are instructive in manufacturing the diamond beads by determining the protrusion height of the diamond grits and the future planning of the cutting parameters.
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Chowdhury MAK, Ullah AS, Teti R. Optimizing 3D Printed Metallic Object's Postprocessing: A Case of Gamma-TiAl Alloys. Materials (Basel) 2021; 14:1246. [PMID: 33808000 DOI: 10.3390/ma14051246] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/02/2021] [Revised: 02/26/2021] [Accepted: 03/03/2021] [Indexed: 11/21/2022]
Abstract
Gamma-TiAl (γ-TiAl) alloys can be used in high-end products relevant to the aerospace, defense, biomedical, and marine industries. Fabricating objects made of γ-TiAl alloys needs an additive manufacturing process called Electron Beam Melting (EBM) or other similar processes because these alloys are difficult-to-cut materials. An object fabricated by EBM exhibits poor surface finish and must undergo postprocessing. In this study, cylindrical specimens were fabricated by EBM and post-processed by turning at different cutting conditions (cutting speed, depth of cut, feed rate, insert radius, and coolant flowrate). The EBM conditions were as follows: average powder size 110 μm, acceleration voltage 60 kV, beam current 10 mA, beam scanning speed 2200 mm/s, and beam focus offset 0.20 mm. The surface roughness and cutting force were recorded for each set of cutting conditions. The values of the cutting conditions were set by the L36 Design of Experiment approach. The effects of the cutting conditions on surface roughness and cutting force are elucidated by constructing the possibility distributions (triangular fuzzy numbers) from the experimental data. Finally, the optimal cutting conditions to improve the surface finish of specimens made of γ-TiAl alloys are determined using the possibility distributions. Thus, this study’s outcomes can be used to develop intelligent systems for optimizing additive manufacturing processes.
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Meng X, Lin Y, Mi S. The Research of Tool Wear Mechanism for High-Speed Milling ADC12 Aluminum Alloy Considering the Cutting Force Effect. Materials (Basel) 2021; 14:ma14051054. [PMID: 33668143 PMCID: PMC7956700 DOI: 10.3390/ma14051054] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 01/26/2021] [Revised: 02/17/2021] [Accepted: 02/19/2021] [Indexed: 11/24/2022]
Abstract
Tool wear is a major cause of accelerated tool failure during the milling of aluminum alloy. The periodically cutting force directly affect the cutting heat and tool wear due to the intermittent cutting characteristics of the milling process. The focus of this paper is to analyze the influence of the variation of cutting force on tool wear behavior. The change law of cutting force by cutting parameters was analyzed firstly. Secondly, the variation of the wear land width (VB) of tool flank face by the milling length was analyzed. Thirdly, the wear morphology and the energy dispersive spectrometer (EDS) results of tool rake face and flank face in different cutting parameters were observed by tungsten filament scanning electron microscope. Finally, considering the cutting force effect, the tool wear mechanism during high-speed milling of Aluminum-Alloy Die Castings 12 (ADC12, 12 means aluminum number 12) was analyzed. The cutting force in tangential direction is predominant during high-speed milling aluminum alloy, which decreases gradually with the increase of cutting speed but increases gradually with the feed rising. The adhesion-oxidation wear was main wear mechanism of tool rake face during high-speed milling. While adhesive wear was the main wear mechanism of the tool flank face during high-speed milling. It is found that the formation of adhesive wear is the process from particle adhesion to melting until the formation of adhesive layer, which related to the change of cutting force.
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Kuntoğlu M, Aslan A, Pimenov DY, Usca ÜA, Salur E, Gupta MK, Mikolajczyk T, Giasin K, Kapłonek W, Sharma S. A Review of Indirect Tool Condition Monitoring Systems and Decision-Making Methods in Turning: Critical Analysis and Trends. Sensors (Basel) 2020; 21:s21010108. [PMID: 33375340 PMCID: PMC7794675 DOI: 10.3390/s21010108] [Citation(s) in RCA: 90] [Impact Index Per Article: 22.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/28/2020] [Revised: 12/20/2020] [Accepted: 12/22/2020] [Indexed: 01/29/2023]
Abstract
The complex structure of turning aggravates obtaining the desired results in terms of tool wear and surface roughness. The existence of high temperature and pressure make difficult to reach and observe the cutting area. In-direct tool condition, monitoring systems provide tracking the condition of cutting tool via several released or converted energy types, namely, heat, acoustic emission, vibration, cutting forces and motor current. Tool wear inevitably progresses during metal cutting and has a relationship with these energy types. Indirect tool condition monitoring systems use sensors situated around the cutting area to state the wear condition of the cutting tool without intervention to cutting zone. In this study, sensors mostly used in indirect tool condition monitoring systems and their correlations between tool wear are reviewed to summarize the literature survey in this field for the last two decades. The reviews about tool condition monitoring systems in turning are very limited, and relationship between measured variables such as tool wear and vibration require a detailed analysis. In this work, the main aim is to discuss the effect of sensorial data on tool wear by considering previous published papers. As a computer aided electronic and mechanical support system, tool condition monitoring paves the way for machining industry and the future and development of Industry 4.0.
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Affiliation(s)
- Mustafa Kuntoğlu
- Mechanical Engineering Department, Technology Faculty, Selcuk University, Selçuklu, 42130 Konya, Turkey;
| | - Abdullah Aslan
- Mechanical Engineering Department, Engineering and Architecture Faculty, Selcuk University, Akşehir, 42130 Konya, Turkey;
| | - Danil Yurievich Pimenov
- Department of Automated Mechanical Engineering, South Ural State University, Lenin Prosp. 76, 454080 Chelyabinsk, Russia;
- Correspondence:
| | - Üsame Ali Usca
- Mechanical Engineering Department, Engineering and Architecture Faculty, Bingöl University, 12000 Bingöl, Turkey;
| | - Emin Salur
- Department of Metallurgical and Materials Engineering, Selcuk University, Selçuklu, 42130 Konya, Turkey;
| | - Munish Kumar Gupta
- Department of Automated Mechanical Engineering, South Ural State University, Lenin Prosp. 76, 454080 Chelyabinsk, Russia;
- Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical Engineering, Shandong University, Jinan 250100, China
| | - Tadeusz Mikolajczyk
- Department of Production Engineering, UTP University of Science and Technology, Al. Prof. S. Kaliskiego 7, 85-796 Bydgoszcz, Poland;
| | - Khaled Giasin
- School of Mechanical and Design Engineering, University of Portsmouth, Portsmouth PO1 3DJ, UK;
| | - Wojciech Kapłonek
- Department of Production Engineering, Faculty of Mechanical Engineering, Koszalin University of Technology, Racławicka 15-17, 75-620 Koszalin, Poland;
| | - Shubham Sharma
- Department of Mechanical Engineering, IKG Punjab Technical University, Jalandhar-Kapurthala Road, Kapurthala, Punjab 144603, India;
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Zawada-Michałowska M, Józwik J, Legutko S, Mika D, Pieśko P, Pytka J. Cutting Force during Surface Layer Milling of Selected Aluminium Alloys. Materials (Basel) 2020; 13:ma13245725. [PMID: 33334039 PMCID: PMC7765542 DOI: 10.3390/ma13245725] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/11/2020] [Revised: 12/09/2020] [Accepted: 12/13/2020] [Indexed: 11/16/2022]
Abstract
This paper presents the analysis of cutting force during surface layer milling of selected aluminium alloys, which are widely used in the aviation industry. The cutting force is one of the most important parameters determining the machinability of the material and also provides important information about the course of the cutting. The study analysed the influence of the technological parameters, i.e., cutting speed vc and depth of cut ap as well as the relation between cutting tool feed direction and rolling direction on the value of cutting force during milling of selected aluminium alloys, i.e., EN AW-2017A T451 and EN AW-2024 T351. The material anisotropy is a very important issue, since the engineering industry faces enormous problems related to the cutting of the tested materials that are usually supplied in the form of rolled plates. The surface layer was cut due to the fact that it accumulates the greatest residual stresses. The measurement process of cutting force was performed by using 9257B Kistler piezoelectric dynamometer. As part of the analysis of the results, the measurement uncertainty was also estimated, which was determined on the basis of two components obtained by using the A and B methods, respectively.
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Affiliation(s)
- Magdalena Zawada-Michałowska
- Faculty of Mechanical Engineering, Lublin University of Technology, 20-618 Lublin, Poland; (J.J.); (P.P.); (J.P.)
- Correspondence: ; Tel.: + 48-81-5384227
| | - Jerzy Józwik
- Faculty of Mechanical Engineering, Lublin University of Technology, 20-618 Lublin, Poland; (J.J.); (P.P.); (J.P.)
| | - Stanisław Legutko
- Faculty of Mechanical Engineering, Poznan University of Technology, 60-965 Poznań, Poland;
| | - Dariusz Mika
- Institute of Technical Sciences and Aviation, The State School of Higher Education in Chelm, 22-100 Chełm, Poland;
| | - Paweł Pieśko
- Faculty of Mechanical Engineering, Lublin University of Technology, 20-618 Lublin, Poland; (J.J.); (P.P.); (J.P.)
| | - Jarosław Pytka
- Faculty of Mechanical Engineering, Lublin University of Technology, 20-618 Lublin, Poland; (J.J.); (P.P.); (J.P.)
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Umer U, Kishawy H, Abidi MH, Mian SH, Moiduddin K. Evaluation of Self-Propelled Rotary Tool in the Machining of Hardened Steel Using Finite Element Models. Materials (Basel) 2020; 13:ma13225092. [PMID: 33187305 PMCID: PMC7697589 DOI: 10.3390/ma13225092] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/12/2020] [Revised: 11/02/2020] [Accepted: 11/09/2020] [Indexed: 11/16/2022]
Abstract
This paper presents a model for assessing the performance of self-propelled rotary tool during the processing of hardened steel. A finite element (FE) model has been proposed in this analysis to study the hard turning of AISI 51200 hardened steel using a self-propelled rotary cutting tool. The model is developed by utilizing the explicit coupled temperature displacement analysis in the presence of realistic boundary conditions. This model does not take into account any assumptions regarding the heat partitioning and the tool-workpiece contact area. The model can predict the cutting forces, chip flow, induced stresses, and the generated temperature on the cutting tool and the workpiece. The nodal temperatures and heat flux data from the chip formation analysis are used to achieve steady-state temperatures on the cutting tool in the heat transfer analysis. The model outcomes are compared with reported experimental data and a good agreement has been found.
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Affiliation(s)
- Usama Umer
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia; (M.H.A.); (S.H.M.); (K.M.)
- Correspondence:
| | - Hossam Kishawy
- Machining Research Laboratory, University of Ontario Institute of Technology, Oshawa, ON L1G 0C5, Canada;
| | - Mustufa Haider Abidi
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia; (M.H.A.); (S.H.M.); (K.M.)
| | - Syed Hammad Mian
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia; (M.H.A.); (S.H.M.); (K.M.)
| | - Khaja Moiduddin
- Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi Arabia; (M.H.A.); (S.H.M.); (K.M.)
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Świć A, Gola A, Sobaszek Ł, Orynycz O. Control of Machining of Axisymmetric Low-Rigidity Parts. Materials (Basel) 2020; 13:E5053. [PMID: 33182507 DOI: 10.3390/ma13215053] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/22/2020] [Revised: 10/22/2020] [Accepted: 11/06/2020] [Indexed: 11/17/2022]
Abstract
The specific character of the process of machining of axisymmetric low-rigidity parts makes it difficult to obtain finished products with a required accuracy of shape and dimensions and surface quality. The methods traditionally used to achieve accuracy in the machining of low-rigidity shafts considerably reduce the efficiency of the process, fail to meet modern automation requirements, and are uneconomical and not very productive, which means new methods for controlling the machining of low-rigidity shafts need to be looked for. This article presents a structural and a calculation scheme of a machining system for the turning of low-rigidity parts and a control model based on the second-order Lagrange equation. The first section of this paper presents qualitative relationships among variables in the proposed technological system for machining axisymmetric low-rigidity parts. Moreover, schematic of the machining system for the processing of such parts as well as equations describing the energy state of the machining system is presented. Next, mathematical model of optimal system control during the machining process, which permits to control a system under specific conditions and obtains a higher shape accuracy were introduced. The key stage of the verification process concerns the numerical validation of proposed solutions. Experimental studies confirm that the utilization of the proposed mathematical models describe the properties of the original object with sufficient accuracy and allow to obtain a higher machined shaft shape accuracy.
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Kino H, Imada T, Ogawa K, Nakagawa H, Kojima H. An Experimental Investigation on Micro End Milling with High-Speed Up Cut Milling for Hardened Die Steel. Materials (Basel) 2020; 13:ma13214745. [PMID: 33114162 PMCID: PMC7660688 DOI: 10.3390/ma13214745] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/02/2020] [Revised: 10/20/2020] [Accepted: 10/21/2020] [Indexed: 11/16/2022]
Abstract
The importance of micromachining using small diameter end mills and the dies used for them has been increasing in the machining of small parts. However, the reality is that there are various requirements to improve the machining surface, machining accuracy, machining efficiency, and tool life. Therefore, this paper discusses the possibility of satisfying these requirements by high-speed up cut milling in side cutting. The goal of this study was to solve the aforementioned problems, by conducting a detailed analysis of the machining phenomena in order to understand their mechanisms. In particular, the effects of high-speed cutting using a high-speed air-turbine spindle with highly stiff rolling bearings were analyzed. Moreover, cutting experiments were conducted by measuring the cutting force and flank wear of the tool, to reveal the differences in the cutting phenomena relative to the cutting direction in high-speed micro end milling. Description of the machined surface and the measurement of its profile were also included in the discussions. On the basis of the results, high-speed up cut milling is a better choice than down cut milling; furthermore, a high-feed rate further increases machining efficiency and improves tool life.
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Affiliation(s)
- Haruki Kino
- MOLDINO Tool Engineering Ltd., Hulic Ryogoku Building 8F, 4-31-11, Ryogoku, Sumida-ku, Tokyo 130-0026, Japan;
| | - Takumi Imada
- Industrial Research Center of Shiga Prefecture, 232 Kamitoyama, Ritto, Shiga 520-3004, Japan;
| | - Keiji Ogawa
- Ryukoku University, 1-5 Yokotani, Seta Oe-cho, Otsu, Shiga 520-2194, Japan
- Correspondence: ; Tel.: +81-77-543-7445
| | - Heisaburo Nakagawa
- Nakagawa Machining R&D Center, 974-1 Nakanoshima, Wakayama 640-8392, Japan;
| | - Hitomi Kojima
- Big Daishowa Seiki Co Ltd., 3-3-39 Nishi-ishikiri-cho, Higashi-Osaka, Osaka 579-8025, Japan;
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Hlaváč LM, Štefek A, Tyč M, Krajcarz D. Influence of Material Structure on Forces Measured during Abrasive Waterjet (AWJ) Machining. Materials (Basel) 2020; 13:E3878. [PMID: 32887394 PMCID: PMC7503880 DOI: 10.3390/ma13173878] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 07/27/2020] [Revised: 08/28/2020] [Accepted: 08/31/2020] [Indexed: 11/29/2022]
Abstract
Material structure is one of the important factors influencing abrasive waterjet (AWJ) machining efficiency and quality. The force measurements were performed on samples prepared from two very similar steels with different thicknesses and heat treatment. The samples were austenitized at 850 °C, quenched in polymer and tempered at various temperatures between 20 °C and 640 °C. The resulting states of material substantially differed in strength and hardness. Therefore, samples prepared from these material states are ideal for testing of material response to AWJ. The force measurements were chosen to test the possible influence of material structure on the material response to the AWJ impact. The results show that differences in material structure and respective material properties influence the limit traverse speed. The cutting to deformation force ratio seems to be a function of relative traverse speed independently on material structure.
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Affiliation(s)
- Libor M. Hlaváč
- Department of Applied Physics, Faculty of Electrical Engineering and Computer Science, VSB–Technical University of Ostrava, 17. listopadu 2172/15, 70800 Ostrava–Poruba, Czech Republic; (A.Š.); (M.T.)
| | - Adam Štefek
- Department of Applied Physics, Faculty of Electrical Engineering and Computer Science, VSB–Technical University of Ostrava, 17. listopadu 2172/15, 70800 Ostrava–Poruba, Czech Republic; (A.Š.); (M.T.)
| | - Martin Tyč
- Department of Applied Physics, Faculty of Electrical Engineering and Computer Science, VSB–Technical University of Ostrava, 17. listopadu 2172/15, 70800 Ostrava–Poruba, Czech Republic; (A.Š.); (M.T.)
| | - Daniel Krajcarz
- Department of Materials Science and Materials Technology, Faculty of Mechatronics and Mechanical Engineering, Kielce University of Technology, al. Tysiąclecia Państwa Polskiego 7, 25-314 Kielce, Poland;
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50
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Chen D, Li S, Fan J. Effect of KDP-Crystal Material Properties on Surface Morphology in Ultra-Precision Fly Cutting. Micromachines (Basel) 2020; 11:E802. [PMID: 32854190 DOI: 10.3390/mi11090802] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 07/21/2020] [Revised: 08/23/2020] [Accepted: 08/23/2020] [Indexed: 11/16/2022]
Abstract
To study the effect of material properties on the surface morphology of potassium dihydrogen phosphate (KDP) crystals, an ultra-precision fly cutting machine tool with a single-point diamond tool was used to perform a cutting experiment on (100) crystal plane of the KDP crystal. The elastic modulus, shear modulus, hardness, and dislocation of KDP crystals are taken into the cutting force model by introducing the strain gradient plasticity theory. Since the size effect and dynamic response will affect the surface roughness during ultra-precision machining, the surface roughness of workpieces in ultra-precision fly cutting is hard to predict. Based on the previously established strain gradient plasticity theoretical model, cutting force model, and the dynamic characteristics of the ultra-precision fly cutting system, a surface morphology prediction model under the influence of KDP crystal material properties was established. Finally, the accuracy of the surface morphology prediction model was verified by ultra-precision fly cutting experiments, and identified the frequency range of the characteristic signal caused by the anisotropy of the KDP crystal from the frequency, thereby verifying the KDP crystal material properties has a significant effect on the surface of the machined workpiece roughness.
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