Search results for "Machining"
showing 10 items of 180 documents
A critical analysis on the friction modelling in orthogonal machining
2007
Abstract Despite the development of high performance finite element-based codes, the simulation of machining still represents a very hard task due to the geometric complexity of the real chip-tool systems and the high cutting speed that requires very long simulation times. For these reasons, many aspects related to machining are not very clear and so easy to simulate. In this paper a rigorous investigation on the role played by the implemented friction model within a 2D simulation of orthogonal cutting was carried out, taking into account different models proposed by the researchers in the last years. The main simulation results were compared with experimental measurements in order to verif…
Improving the Performance of Steel Machining Processes through Cutting by Vibration Control
2021
Machining processes through cutting are accompanied by dynamic phenomena that influence the quality of the processed surfaces. Thus, this research aimed to design, make, and use a tool with optimal functional geometry, which allowed a reduction of the dynamic phenomena that occur in the cutting process. In order to carry out the research, the process of cutting by front turning with transversal advance was taken into account. Additionally, semi-finished products with a diameter of Ø = 150 mm made of C45 steel were chosen for processing (1.0503). The manufacturing processes were performed with the help of two tools: a cutting tool, the classic construction version, and another that was the i…
Mechanical and microstructural characterization of titanium gr.5 parts produced by different manufacturing routes
2022
Abstract In recent years, the aircraft industry has shifted its preference for metal parts to titanium and its alloys, such as the high-strength Titanium Grade5 alloy. Because of Titanium Grade 5 limited formability at ambient temperature, forming operations on this material require high temperatures. In these conditions, a peculiar microstructure evolves as a result of the heating and deformation cycles, which has a significant impact on formability and product quality. On the other hand, additive manufacturing technologies, as selective laser melting and electron beam melting, are increasingly being used and are replacing more traditional approaches such as machining and forging. Fundamen…
The performance of molybdenum toughened alumina cutting tools in turning a particulate metal matrix composite
2003
In this paper, a study of the tool wear mechanism in turning aluminium alloy reinforced with alumina using molybdenum-toughened alumina tools is presented. Alumina tools with three different amounts (15, 20 and 25 vol.%) of molybdenum were prepared and tested. The wear type was identified and its evolution with cutting time was measured. The results show that the main mechanism of tool wear is abrasion and not heat. The best overall performance was achieved, as far as flank wear is concerned, using the tool with 20 vol.% of molybdenum added. This has been explained using some of the composites intrinsic properties. SEM examination revealed that molybdenum particles are easily torn from the …
Wear mechanisms and residual stresses in alumina-based laminated cutting tools
2005
Abstract The outstanding performances of the Al2O3 cutting tools in terms of potential cutting speed can lead to substantial economies in the machining of metallic materials. Nevertheless, their widespread use is limited by some drawbacks such as the tendency to edge chipping and to the propagation of microcracks, which can lead to premature failures. These shortcomings are due to the intrinsic low toughness of the ceramic material, which is in turn related to its characteristics non-metallic bonds. A well-recognised method of increasing the toughness of brittle materials is the introduction of surface compressive stresses, which can be obtained through a suitable lamination geometry of the…
Wear of Ceramic Tools When Working Nickel Based Alloys
1996
In order to improve the toughness of alumina materials, various trials have recently been made. These include toughening by the addition of zirconia and of significant amounts of titanium carbide to ceramic oxide Al2O3 and the more recent use of nitride based ceramics, which have resulted in an increase of fracture toughness and in a significant improvement of ceramic tool performance. Another very recent way of improving ceramic materials consists in adding SiC whiskers to Al2O3 matrix. This composite material is also suitable for machining nickel based alloys. In order to evaluate and to qualify these materials some test cycles have been carried out in continuous cutting conditions, emplo…
Different Methods of Artificial Intelligence Used for Optimization the Turning Process
2015
In this paper, we realize a comparative study between some heuristics methods applied in turning operation in order to find optimal cutting parameters. We consider five different constraints aimed to achieve minimum total cost of machining. We have chosen the Simulated Annealing (SA) – a local search method, and Weighted-Sum Genetic Algorithm (WSGA) – a non-Pareto approach of a multi-objective optimization algorithm, based on a weighted aggregation of objectives. The aggregation may be with fixed weights or with random (variable) weights. The simulations showed that, even if it produces better results than the SA, WSGA with fixed weights, does not lead to optimum results, highlighting in th…
Cutting Vibrations
2008
Chapter 8 provides comprehensive engineering knowledge regarding cutting vibrations, their typical sources in machining operations, and methods of their elimination to prevent negative influence on the surface finish (chatter marks). The classification of cutting vibrations including free, forced, and self-excited vibrations is discussed, and all possible sources and mechanisms of all types of cutting vibrations are specified and characterized. The regeneration of surface waviness, which is the predominant mechanism of chatter, is outlined for turning and milling operations. The stability of machining operations based on the stability lobe diagrams is highlighted and their practical applica…
On the FE codes capability for tool temperature calculation in machining processes
2006
Abstract The applications of numerical simulation to machining processes have been more and more growing in the last years: today a quite effective predictive capability has been reached, at least as far as global cutting variables (for instance cutting forces) are concerned. On the other hand, the capability to predict local cutting variables (i.e. pressure on the tool, temperature distribution, residual stresses in the machined surface) has to be heavily improved and verified. At the same time, effective experimental procedures for validating numerical results have to be developed. In this work two different approaches were implemented for temperature measuring: a thermocouple based appro…
Cutting Conditions and Work Material State Identification through Acoustic Emission Methods
1992
Summary This paper examines the problem of in-process monitoring of metal cutting operations carried out on aluminum alloys for aeronautical applications. Turning tests were conducted on annealed and heat treated aluminum alloy bars, using carbide tools. For both work material conditions, different combinations of cutting parameters were used. During cutting tests, acoustic emission (AE) and cutting force sensor data were detected and processed. The comparison between AE responses from the annealed and heat treated aluminum alloys allowed, with the help of force sensor data, to verify the applicability of AE and sensor fusion techniques for in-process and real time identification of work ma…