Showing papers on "Machining published in 2006"
TL;DR: In this article, the main drivers, developments and future requirements in the field of micromanufacturing as related to the machining process from the perspective of the recent research and development literature are reviewed.
738 citations
Book•
01 Jan 2006
TL;DR: The International (SI) system of units (SI-system of units) as mentioned in this paper is used to measure the strength of a cutting tool and the size effect of the forces acting on the cutting tool.
Abstract: CONVENTIONS USED IN THIS BOOK Standardization Introduction to the International (SI) System of Units MACHINE TOOLS AND MACHINING OPERATIONS Introduction Generating Motions of Machine Tools Machines Using Single-Point Tools Machines Using Multipoint Tools Machines Using Abrasive Wheels Summary of Machine Tool Characteristics and Machining Equations Problems References MECHANICS OF METAL CUTTING Introduction Terms and Definitions Chip Formation The Forces Acting on the Cutting Tool and Their Measurement Specific Cutting Energy Plowing Force and the "Size Effect" The Apparent Mean Shear Strength of the Work Material Chip Thickness Friction in Metal Cutting Analytical Modeling of Machining Operations Problems References TEMPERATURES IN METAL CUTTING Heat Generation in Metal Cutting Heat Transfer in a Moving Material Temperature Distribution in Metal Cutting The Measurement of Cutting Temperatures Problems References TOOL LIFE AND TOOL MATERIALS Introduction Progressive Tool Wear Forms of Wear in Metal Cutting The Tool Material Tool Geometries The Work Material High Speed Machining Hard Machining Problems References CUTTING FLUIDS AND SURFACE ROUGHNESS Cutting Fluids The Action of Coolants The Action of Lubricants Application of Cutting Fluids Cutting Fluid Maintenance Environmental Considerations Disposal of Cutting Fluids Dry Cutting and Minimum Quantity Lubrication Surface Roughness Tool Geometries for Improved Surface Finish Burr Formation in Machining Problems References ECONOMICS OF METAL-CUTTING OPERATIONS Introduction Choice of Feed Choice of Cutting Speed Tool Life for Minimum Cost and Minimum Production Time Estimation of Factors Needed to Determine Optimum Conditions Example of a Constant-Cutting-Speed Operation Machining at Maximum Efficiency Facing Operations Operations with Interrupted Cuts Economics of Various Tool Materials and Tool Designs Machinability Data Systems Limitations of Available Machinability Data Problems References NOMENCLATURE OF CUTTING TOOLS Introduction Systems of Cutting-Tool Nomenclature International Standard Problems References CHIP CONTROL Introduction Chip Breakers Prediction of Radius of Chip Curvature Prediction of Chip Breaking Performance Tool Wear During Chip Breaking Problems References MACHINE TOOL VIBRATIONS Introduction Forced Vibrations Self-Excited Vibrations (Chatter) Determination of Frequency Response Loci Dynamic Acceptance Tests for Machine Tools Improving Machine Tool Stability Problems References GRINDING Introduction The Grinding Wheel Effect of Grinding Conditions on Wheel Behavior Determination of the Density of Active Grains Testing of Grinding Wheels Dressing and Truing of Grinding Wheels Analysis of the Grinding Process Thermal Effects in Grinding Cutting Fluids in Grinding Grinding-Wheel Wear Nonconventional Grinding Operations Problems References MANUFACTURING SYSTEMS AND AUTOMATION Introduction Types of Production Types of Facilities Layout Types of Automation Transfer Machines Automatic Machines Numerically Controlled (NC) Machine Tools Comparison of the Economics of Various Automation Systems Handling of Components in Batch Production Flexible Manufacturing Systems Problems References COMPUTER-AIDED MANUFACTURING Introduction Scope of CAD/CAM Process-Planning Tasks Computer-Aided Process Planning Processing of NC Programs Computer-Aided NC Processing Numerical Control Processing Languages NC Programming Using APT-Based Languages Graphics-Based NC Processing Systems References DESIGN FOR MACHINING Introduction Standardization Choice of Work Material Shape of Work Material Shape of Component Assembly of Components Accuracy and Surface Finish Summary of Design Guidelines Cost Estimating for Machined Components Problems References NONCONVENTIONAL MACHINING PROCESSES Introduction Range of Nonconventional Machining Processes Ultrasonic Machining Water-Jet Machining Abrasive-Jet Machining Chemical Machining Electrochemical Machining Electrolytic Grinding Electrical-Discharge Machining Wire Electrical-Discharge Machining Laser-Beam Machining Electron-Beam Machining Plasma-Arc Cutting Comparative Performance of Cutting Processes Problems References NOMENCLATURE INDEX
556 citations
TL;DR: In this article, the authors present a review of previous research on heat generation and heat dissipation in the orthogonal machining process and propose some modelling requirements for computer simulation of high speed machining processes.
Abstract: Determination of the maximum temperature and temperature distribution along the rake face of the cutting tool is of particular importance because of its controlling influence on tool life, as well as, the quality of the machined part. Numerous attempts have been made to approach the problem with different methods including experimental, analytical and numerical analysis. Although considerable research effort has been made on the thermal problem in metal cutting, there is hardly a consensus on the basics principles. The unique tribological contact phenomenon, which occur in metal cutting is highly localized and non-linear, and occurs at high temperatures, high pressures and high strains. This has made it extremely difficult to predict in a precise manner or even assess the performance of various models developed for modelling the machining process. Accurate and repeatable heat and temperature prediction remains challenging due to the complexity of the contact phenomena in the cutting process. In this paper, previous research on heat generation and heat dissipation in the orthogonal machining process is critically reviewed. In addition, temperature measurement techniques applied in metal cutting are briefly reviewed. The emphasis is on the comparability of test results, as well as, the relevance of temperature measurement method to high speed cutting. New temperature measurement results obtained by a thermal imaging camera in high speed cutting of high strength alloys are also presented. Finally, the latest work on estimation of heat generation, heat partition and temperature distribution in metal machining is reviewed. This includes an exploration of the different simplifying assumptions related to the geometry of the process components, material properties, boundary conditions and heat partition. The paper then proposes some modelling requirements for computer simulation of high speed machining processes.
541 citations
Book•
21 Dec 2006TL;DR: In this article, the authors discuss the importance of the use of a brasive wheel for a purpose problem-solving task and the nature of the abrasive wheel's mechanism.
Abstract: THE BASIC PROCESS OF GRINDING Introduction From Craft to Science Basic Uses of Grinding Elements of the Grinding System The Importance of the Abrasive Grinding Wheels for a Purpose Problem Solving References Grinding Parameters Introduction Process Parameters Grinding Temperatures Appendix: Drawing Form and Profile Tolerancing References Material Removal Mechanisms Significance Grinding Wheel Topography Determination of Grinding Wheel Topography Kinematics of the Cutting Edge Engagement Fundamental Removal Mechanisms Material Removal in Grinding of Ductile Materials Surface Formation in Grinding of Brittle-Hard Materials Energy Transformation References Grinding Wheels Introduction Wheel Shape Specification Wheel Balance Design of High-Speed Wheels Bond Life Wheel Mount Design Wheel Design and Chatter Suppression References The Nature of the Abrasive Introduction Silicon Carbide Alumina (Alox)-Based Abrasives Electrofused Alumina Abrasives Chemical Precipitation and/or Sintering of Alumina Diamond Abrasives CBN Grain Size Distributions Future Grain Developments Postscript References Specification of the Bond Introduction Single-Layer Wheels Electroplated (EP) Single-Layer Wheels Brazed Single-Layer Wheels Vitrified Bond Wheels for Conventional Wheels Vitrified Bonds for Diamond Wheels Vitrified Bonds for CBN Resin Bond Wheels Plastic Bonds Phenolic Resin Bonds Polyimide Resin Bonds Metal Bonds Other Bond Systems References Dressing Introduction Traverse Dressing of Conventional Vitrified Wheels with Stationary Tools Traverse Dressing of Superabrasive Wheels with Stationary Tools Uniaxial Traverse Dressing of Conventional Wheels with Rotary Diamond Tools Uniaxial Traverse Dressing of Vitrified CBN Wheels with Rotary Diamond Tools Cross-Axis Traverse Dressing with Diamond Discs Diamond Form-Roll Dressing Truing and Conditioning of Superabrasive Wheels References Grinding Dynamics Introduction Forced and Regenerative Vibrations The Effect of Workpiece Velocity Geometrical Interference between Grinding Wheel and Workpiece Vibration Behavior of Various Grinding Operations Regenerative Self-Excited Vibrations Suppression of Grinding Vibrations Conclusions References Grinding Wheel Wear Three Types of Wheel Wear Wheel Wear Mechanisms Wear of the Abrasive Grains Bond Wear Assessment of Wheel Wear References Coolants Introduction Basic Properties of Grinding Fluids Types of Grinding Fluids Base Materials Additives Application Results Environmental Aspects The Supply System Grinding Fluid Nozzles Influence of the Grinding Fluid in Grinding References Monitoring of Grinding Processes The Need for Process Monitoring Sensors for Monitoring Process Variables Sensor for Monitoring the Grinding Wheel Sensors for Monitoring the Workpiece Sensors for Peripheral Systems References Economics of Grinding Introduction A Grinding Cost Comparison Based on an Available Grinding Machine A Cost Comparison Including Capital Investment Cost Comparison Including Tooling Grinding as a Replacement for Other Processes Multitasking Machines for Hard-Turning with Grinding Summary References APPLICATION OF GRINDING PROCESSES Grinding of Ductile Materials Introduction Cast Irons Steels Heat-Resistant Superalloys References Grinding of Ceramics Introduction Background on Ceramic Materials Diamond Wheels for Grinding Ceramics Physics of Grinding Ceramics ELID Grinding of Ceramics References Grinding Machine Technology The Machine Base Foundations Guideways Slideway Configurations Hydrostatic Slideways Recirculating Rolling Element Slideways Linear Axis Drives and Motion Control Elements of AC Servodrive Ballscrew Systems Linear Motor Drive Systems Spindle Motors and Grinding Wheel Drives Drive Arrangements for Large Conventional Wheels Drive Arrangements for Small Wheel Spindle Units Spindles for High-Speed Grinding Miscellaneous Wheel Spindles and Drives Rotary Dressing Systems Power and Stiffness Requirements for Rotary Dressers Rotary Dressing Spindle Examples Dressing Infeed System References Surface Grinding Types of Surface Grinding Process Basics of Reciprocating Grinding Basics of Creep Grinding Basics of Speed-Stroke Grinding Successful Application of Creep Feed Grinding Face Grinding Fine Grinding Appendix: Lapping Kinematics References External Cylindrical Grinding The Basic Process High-Speed Grinding Automotive Camlobe Grinding Punch Grinding Crankshaft Grinding Roll Grinding References Internal Grinding Introduction The Internal Grinding Process Abrasive Type Process Parameters Machine Tool Selection Troubleshooting References Centerless Grinding The Importance of Centerless Grinding Basic Process Basic Relationships Feed Processes Centerless Wheel and Dressing Geometry The Workrest Speed Control Machine Structure High Removal Rate Grinding Economic Evaluation of Conventional and CBN Wheels The Mechanics of Rounding Vibration Stability Dynamic Stability Avoiding Critical Frequencies Summary and Recommendations for Rounding Process Control References Ultrasonic Assisted Grinding Introduction Ultrasonic Technology and Process Variants Ultrasonic-Assisted Grinding with Workpiece Excitation Peripheral Grinding with Radial Ultrasonic Assistance Peripheral Grinding with Axial Ultrasonic Assistance Ultrasonic-Assisted Grinding with Excitation of the Wheel Summary References Glossary Notation and Use of SI Units Index
468 citations
TL;DR: In this article, the role of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel at industrial speed-feed combination by uncoated carbide insert was investigated.
432 citations
TL;DR: In this article, the use of grey relational analysis for optimising the drilling process parameters for the work piece surface roughness and the burr height is introduced, where various drilling parameters, such as feed rate, cutting speed, drill and point angles of drill were considered.
Abstract: The theory of grey systems is a new technique for performing prediction, relational analysis and decision making in many areas. In this paper, the use of grey relational analysis for optimising the drilling process parameters for the work piece surface roughness and the burr height is introduced. Various drilling parameters, such as feed rate, cutting speed, drill and point angles of drill were considered. An orthogonal array was used for the experimental design. Optimal machining parameters were determined by the grey relational grade obtained from the grey relational analysis for multi-performance characteristics (the surface roughness and the burr height). Experimental results have shown that the surface roughness and the burr height in the drilling process can be improved effectively through the new approach .
394 citations
TL;DR: In this paper, the authors examined the theoretical predictions of critical thrust force at the onset of delamination, and compared the effects of different drill bits, including saw drill, candle stick drill, core drill and step drill.
Abstract: Drilling is the most frequently employed operation of secondary machining for fiber-reinforced materials owing to the need for joining structures Delamination is among the serious concerns during drilling Practical experience proves the advantage of using such special drills as saw drill, candle stick drill, core drill and step drill The experimental investigation described in this paper examines the theoretical predictions of critical thrust force at the onset of delamination, and compares the effects of these different drill bits The results confirm the analytical findings and are consistent with the industrial experience Ultrasonic scanning is used to evaluate the extent of drilling-induced delamination The advantage of these special drills is illustrated mathematically as well as experimentally, that their thrust force is distributed toward the drill periphery instead of being concentrated at the center The allowable feed rate without causing delamination is also increased The analysis can be extended to examine the effects of other future innovative drill bits
373 citations
TL;DR: In this article, an updated Lagrangian finite element formulation is used to simulate continuous chip formation process in orthogonal cutting of low carbon free-cutting steel, and the effects of tool-chip interfacial friction models on the finite element simulations are investigated.
Abstract: In the analysis of orthogonal cutting process using finite element (FE) simulations, predictions are greatly influenced by two major factors; a) flow stress characteristics of work material at cutting regimes and b) friction characteristics mainly at the tool-chip interface. The uncertainty of work material flow stress upon FE simulations may be low when there is a constitutive model for work material that is obtained empirically from high-strain rate and temperature deformation tests. However, the difficulty arises when one needs to implement accurate friction models for cutting simulations using a particular FE formulation. In this study, an updated Lagrangian finite element formulation is used to simulate continuous chip formation process in orthogonal cutting of low carbon free-cutting steel. Experimentally measured stress distributions on the tool rake face are utilized in developing several different friction models. The effects of tool-chip interfacial friction models on the FE simulations are investigated. The comparison results depict that the friction modeling at the tool-chip interface has significant influence on the FE simulations of machining. Specifically, variable friction models that are developed from the experimentally measured normal and frictional stresses at the tool rake face resulted in most favorable predictions. Predictions presented in this work also justify that the FE simulation technique used for orthogonal cutting process can be an accurate and viable analysis as long as flow stress behavior of the work material is valid at the machining regimes and the friction characteristics at the tool-chip interface is modeled properly.
361 citations
TL;DR: In this article, the role of MQL on cutting temperature, chip formation and product quality in turning AISI-1040 steel at different industrial speed-feed combinations by uncoated carbide insert was investigated.
314 citations
TL;DR: In this article, an existing transient, three-dimensional heat transfer model is modified for modeling LAM of Inconel 718, and suitable coating conditions are determined for increasing the laser absorptivity in metals.
Abstract: Superalloys have high strengths at elevated temperatures, which make them attractive toward various applications and also make these materials difficult to machine at room temperature due to excessive tool wear and poor surface finish. Laser-assisted machining (LAM) offers the ability to machine superalloys more efficiently and economically by providing the local heating of the workpiece prior to material removal by a single point cutting tool. An existing transient, three-dimensional heat transfer model is modified for modeling LAM of Inconel 718. Suitable coating conditions are determined for increasing the laser absorptivity in metals and an approximate absorptivity value is determined. The thermal model is validated in axial and circumferential directions by temperature measurement using an infrared camera. The machinability of Inconel 718 under varying conditions is evaluated by examining tool wear, forces, surface roughness, and specific cutting energy. With increasing material removal temperature from room temperature to 620 °C, the benefit of LAM is demonstrated by a 25% decrease in specific cutting energy, a 2–3-fold improvement in surface roughness and a 200–300% increase in ceramic tool life over conventional machining. Moreover, an economic analysis shows significant benefits of LAM of Inconel 718 over conventional machining with carbide and ceramic inserts.
303 citations
TL;DR: In this article, the influence of wear resistance, thermal stability and hardness of PVD coatings in relation to metal cutting tests such as milling and drilling is discussed. But, the effect of these properties on Al-based nitride coatings on metal cutting performance is not discussed.
Abstract: Modern, state-of-the-art, PVD coatings are required to fulfill a variety of different applications. Each metal cutting operation requires an optimal combination of various film parameters to achieve a high end cutting performance. Especially, Al-based coatings such as AlTiN- and AlCrN-coatings show very good results in high performance metal cutting applications. Wear resistance, thermal stability such as oxidation resistance and hardness at elevated temperatures are key issues within these cutting operations. In this paper the influence of these properties on Al-based nitride coatings in relation to metal cutting tests such as milling and drilling will be discussed.
TL;DR: In this article, the authors presented the underline mechanism and theoretical analysis to provide physical understanding for the onset of chatter problem and principles to prevent that, and the guidelines of process configuration and parameter selections to achieve chatter free machining operation.
TL;DR: In this article, the authors presented an effective approach for the optimization of the wire electric discharge machining (WEDM) process of Al2O3 particle-reinforced material (6061 alloy) with multiple performance characteristics based on the grey relational analysis.
TL;DR: In this paper, an analytical model has been developed to predict the minimum chip thickness values, which are critical for the process model development and process planning and optimization, and the model accounts for the effects of thermal softening and strain hardening on the minimum chips thickness.
Abstract: In micromachining, the uncut chip thickness is comparable or even less than the tool edge radius and as a result a chip will not be generated if the uncut chip thickness is less than a critical value, viz., the minimum chip thickness. The minimum chip thickness effect significantly affects machining process performance in terms of cutting forces, tool wear, surface integrity, process stability, etc. In this paper, an analytical model has been developed to predict the minimum chip thickness values, which are critical for the process model development and process planning and optimization. The model accounts for the effects of thermal softening and strain hardening on the minimum chip thickness. The influence of cutting velocity and tool edge radius on the minimum chip thickness has been taken into account. The model has been experimentally validated with 1040 steel and A16082-T6 over a range of cutting velocities and tool edge radii. The developed model has then been applied to investigate the effects of cutting velocity and edge radius on the normalized minimum chip thickness for various carbon steels with different carbon contents and A16082-T6.
TL;DR: In this paper, a multi response optimization method using Taguchi's robust design approach is proposed for wire electrical discharge machining (WEDM) operations, where the machining parameters are optimized with the multi response characteristics of the material removal rate, surface roughness, and wire wear ratio.
Abstract: In this present study a multi response optimization method using Taguchi’s robust design approach is proposed for wire electrical discharge machining (WEDM) operations. Experimentation was planned as per Taguchi’s L16 orthogonal array. Each experiment has been performed under different cutting conditions of pulse on time, wire tension, delay time, wire feed speed, and ignition current intensity. Three responses namely material removal rate, surface roughness, and wire wear ratio have been considered for each experiment. The machining parameters are optimized with the multi response characteristics of the material removal rate, surface roughness, and wire wear ratio. Multi response S/N (MRSN) ratio was applied to measure the performance characteristics deviating from the actual value. Analysis of variance (ANOVA) is employed to identify the level of importance of the machining parameters on the multiple performance characteristics considered. Finally experimental confirmation was carried out to identify the effectiveness of this proposed method. A good improvement was obtained.
TL;DR: In this paper, a new cooling system was used to lower the temperature of compressed nitrogen gas, and the experimental results show that the cooling/lubrication condition for CCNGOM provided the best tool life among all the cooling and lubrication conditions employed.
TL;DR: In this paper, the surface texture before and after post-deposition treatment was analyzed by means of the Abbot-firestone ratio curves, which showed that the nc-AlTiN-based coatings have high oxidation resistances due to formation of aluminum oxide surface layers, which can result in enhancement of frictional characteristics at the tool/workpiece interface and chip evacuation process.
Abstract: The austenitic stainless steels in general are considered to be difficult to machine materials. This is mainly due to the high plasticity and tendency to work-harden of the austenitic stainless steel, which usually results in severe cutting conditions. Additionally, austenitic stainless steels have much lower thermal conductivity as compared to structural carbon steels; this inflicts high thermal impact within the chip-tool contact zone, which significantly increase the cutting tool wear rate. The machineability of austenitic stainless steels can be improved due to application of coated cutting tools. Hard PVD coating with low thermal conductivity and improved surface finish should be used in this case. This can result in enhancement of frictional characteristics at the tool/workpiece interface as well as chip evacuation process. In this study the stainless steel plates were machined using cemented carbide finishing end mills with four high aluminum containing PVD coatings namely: AlCrN, AlCrNbN, fine grained (fg) AlTiN and nano-crystalline (nc) AlTiN. Both AlTiN and AlCrN-based coatings have high oxidation resistances due to formation of aluminum oxide surface layers. The influence of surface post-deposition treatment on tool wear intensity was investigated. The coating surface texture before and after post-deposition treatment was analyzed by means of the Abbot-Firestone ratio curves. Minimal wear intensity after length of cut 150 m was achieved for cutting tools with the nc-AlTiN coating.
TL;DR: Inconel 718 is one of a family of nickel-based superalloys that are used extensively by the aerospace industry in the hot sections of gas turbine engines as mentioned in this paper.
15 Mar 2006-Jsme International Journal Series C-mechanical Systems Machine Elements and Manufacturing
TL;DR: In this article, the authors give an overview of recent developments in machining and high speed machining of titanium alloys, geometrical modeling of HSM, and cutting force models for HSM of binder-less CBN tools.
Abstract: Titanium alloys have been widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. However, it is very difficult to machine them due to their poor machinability. When machining titanium alloys with conventional tools, the tool wear rate progresses rapidly, and it is generally difficult to achieve a cutting speed of over 60m/min. Other types of tool materials, including ceramic, diamond, and cubic boron nitride (CBN), are highly reactive with titanium alloys at higher temperature. However, binder-less CBN (BCBN) tools, which do not have any binder, sintering agent or catalyst, have a remarkably longer tool life than conventional CBN inserts even at high cutting speeds. In order to get deeper understanding of high speed machining (HSM) of titanium alloys, the generation of mathematical models is essential. The models are also needed to predict the machining parameters for HSM. This paper aims to give an overview of recent developments in machining and HSM of titanium alloys, geometrical modeling of HSM, and cutting force models for HSM of titanium alloys.
TL;DR: In this paper, a two-part paper, milling force, part and tool deflection, form error and stability models are presented to check the process constraints as well as optimal selection of the cutting conditions for high performance milling.
Abstract: Milling is one of the most common manufacturing processes in industry. Despite recent advances in machining technology, productivity in milling is usually reduced due to the process limitations such as high cutting forces and stability. If milling conditions are not selected properly, the process may result in violations of machine limitations and part quality, or reduced productivity. The usual practice in machining operations is to use experience-based selection of cutting parameters which may not yield optimum conditions. In this two-part paper, milling force, part and tool deflection, form error and stability models are presented. These methods can be used to check the process constraints as well as optimal selection of the cutting conditions for high performance milling. The use of the models in optimizing the process variables such as feed, depth of cut and spindle speed are demonstrated by simulations and experiments.
TL;DR: In this article, the authors present an experimental study of the tool wear propagation and cutting force variations in the end milling of Inconel 718 with coated carbide inserts.
TL;DR: In this paper, an analytical method that uses Timoshenko beam theory for calculating the tool point FRF of a given combination by using the receptance coupling and structural modification methods is presented.
Abstract: Regenerative chatter is a well-known machining problem that results in unstable cutting process, poor surface quality and reduced material removal rate. This undesired self-excited vibration problem is one of the main obstacles in utilizing the total capacity of a machine tool in production. In order to obtain a chatter-free process on a machining center, stability diagrams can be used. Numerically or analytically, constructing the stability lobe diagram for a certain spindle–holder–tool combination implies knowing the system dynamics at the tool tip; i.e., the point frequency response function (FRF) that relates the dynamic displacement and force at that point. This study presents an analytical method that uses Timoshenko beam theory for calculating the tool point FRF of a given combination by using the receptance coupling and structural modification methods. The objective of the study is two fold. Firstly, it is aimed to develop a reliable mathematical model to predict tool point FRF in a machining center so that chatter stability analysis can be done, and secondly to make use of this model in studying the effects of individual bearing and contact parameters on tool point FRF so that better approaches can be found in predicting contact parameters from experimental measurements. The model can also be used to study the effects of several spindle, holder and tool parameters on chatter stability. In this paper, the mathematical model, as well as the details of obtaining the system component (spindle, holder and tool) dynamics and coupling them to obtain the tool point FRF are given. The model suggested is verified by comparing the natural frequencies of an example spindle–holder–tool assembly obtained from the model with those obtained from a finite element software. r 2006 Elsevier Ltd. All rights reserved.
TL;DR: In this paper, the results of experimental work in dry turning of austenitic stainless steels (AISI 304 and AISI 316) using CVD multi-layer coated cemented carbide tools were presented.
TL;DR: In this paper, an attempt has been made to assess the influence of machining parameters on the machining of glass fiber-reinforced polymers (GFRP) composite materials in many different engineering fields.
TL;DR: In this article, the authors conceived a new drilling method that imparts a low-frequency, high amplitude vibration to the workpiece in the feed direction during drilling, using high speed steel (HSS) drill, a series of vibratory drilling and conventional drilling experiments were conducted on glass fiber-reinforced plastics composites to assess thrust force, flank wear and delamination factor.
Abstract: The anisotropy of fiber-reinforced plastics (FRP) affects the chip formation and thrust force during drilling. Delamination is recognized as one of the major causes of damage during drilling of fiber reinforced plastics, which not only reduces the structural integrity, but also has the potential for long-term performance deterioration. It is difficult to produce good quality holes with high efficiency by conventional drilling method. This research concerning drilling of polymeric composites aims to establish a technology that would ensure minimum defects and longer tool life. Specifically, the authors conceived a new drilling method that imparts a low-frequency, high amplitude vibration to the workpiece in the feed direction during drilling. Using high-speed steel (HSS) drill, a series of vibratory drilling and conventional drilling experiments were conducted on glass fiber-reinforced plastics composites to assess thrust force, flank wear and delamination factor. In addition, the process-status during vibratory drilling was also assessed by monitoring acoustic emission from the workpiece. From the drilling experiments, it was found that vibratory drilling method is a promising machining technique that uses the regeneration effect to produce axial chatter, facilitating chip breaking and reduction in thrust force.
TL;DR: The authors summarizes the traditional purposes of cutting fluids and reports on recent analytical and experimental research to critically examine these functions and to minimize or even eliminate the concerns associated with cutting fluid usage, several recent and novel approaches have been proposed and examined.
Abstract: Cutting fluids have seen extensive use and have commonly been viewed as a required addition to high productivity and high quality machining operations. Cutting fluid related costs and health concerns associated with exposure to cutting fluid mist and a growing desire to achieve environmental sustainability in manufacturing have caused industry and academia to re-examine the role of these fluids and quantify their benefits. This work summarizes the traditional purposes of cutting fluids and reports on recent analytical and experimental research to critically examine these functions. To minimize or even eliminate the concerns associated with cutting fluid usage, several recent and novel approaches have been proposed and are examined.
TL;DR: In this paper, the role of solid lubricant assisted machining with graphite and molybdenum disulphide lubricants on surface quality, cutting forces and specific energy while machining AISI 1045 steel using cutting tools of different tool geometry.
Abstract: Milling is a widely employed material removal process for different materials. It is characterized by high material removal rate. Machining leads to high friction between tool and workpiece, and can result in high temperatures, impairing the dimensional accuracy and the surface quality of products. Application of conventional cutting fluid may not effectively control the heat generation in milling. Besides, cutting fluids are a major source of pollution. Solid lubricant assisted machining is an environmental friendly clean technology for desirable control of cutting temperature. The present work investigates the role of solid lubricant assisted machining with graphite and molybdenum disulphide lubricants on surface quality, cutting forces and specific energy while machining AISI 1045 steel using cutting tools of different tool geometry (radial rake angle and nose radius). The performance of solid lubricant assisted machining has been studied in comparison with that of wet machining. The results indicate that there is a considerable improvement in the process performance with solid lubricant assisted machining as compared to that of machining with cutting fluids.
TL;DR: In this paper, a mechanics model for predicting the forces of cutting aluminum-based SiC/Al2O3 particle reinforced MMCs is presented, which is considered to be due to three factors: (a) the chip formation force, (b) the ploughing force and (c) the particle fracture force.
Abstract: This paper presents a mechanics model for predicting the forces of cutting aluminum-based SiC/Al2O3 particle reinforced MMCs. The force generation mechanism was considered to be due to three factors: (a) the chip formation force, (b) the ploughing force, and (c) the particle fracture force. The chip formation force was obtained by using Merchant's analysis but those due to matrix ploughing deformation and particle fracture were formulated, respectively, with the aid of the slip line field theory of plasticity and the Griffith theory of fracture. A comparison of the model predictions with the authors’ experimental results and those published in the literature showed that the theoretical model developed has captured the major material removal/deformation mechanisms in MMCs and describes very well the experimental measurements.
TL;DR: In this paper, the effect of cutting speed and feed rate on tool wear (tool life), surface roughness, and cutting forces of the cBN-TiN coated carbide inserts was experimented and analyzed using analysis of variance (ANOVA) technique, and the cutting conditions for their maximum tool life were evaluated.
01 Jan 2006
TL;DR: In this article, an Intelligent Nanofabrication Probe with Function of Surface Displacement/Profile Measurement Smart Transducer Interface Standards for Condition Monitoring and Control of Machines Rocket Testing and Integrated System Health Management.
Abstract: Monitoring and Control of Machining Precision Manfacturing Process Monitoring with Acoustic Emission Tool Condition Monitoring in Machining Monitoring System for Grinding Processes Condition Monitoring of Rotary Machines Advanced Diagnostic and Prognostic Techniques for Rolling Element Bearings Sensor Placement and Signal Processing for Bearing Condition Monitoring Monitoring and Diagnosis of Sheet Metal Stamping Processes Robust State Indicators of Gearboxes Using Adaptive Parametric Modeling Signal Processing in Manufacturing Monitoring Autonomous Active-Sensor Networks for High-Accuracy Monitoring in Manfacturing Remote Monitoring and Control in Distributed Manufacturing Environment An Intelligent Nanofabrication Probe with Function of Surface Displacement/Profile Measurement Smart Transducer Interface Standards for Condition Monitoring and Control of Machines Rocket Testing and Integrated System Health Management