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Characterization & modeling of chip flow angle & morphology in 2D & 3D turning process
University West, Department of Engineering Science, Research Enviroment Production Technology West. (PTW)ORCID iD: 0000-0003-3877-9067
2015 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Within manufacturing of metallic components, machining plays an important role and is of vital significance to ensure process reliability. From a cutting tool design perspective,  tool macro geometry  design  based on physics based  numerical modelling  is highly needed  that can predict chip morphology.  The chip morphology describes the chip shape geometry and the chip curl geometry. The prediction of chip flow and chip shape is vital in predicting chip breakage, ensuring good chip evacuation and lower surface roughness.  To this end, a platform where such a  numerical model’s chip morphology prediction  can be compared with experimental investigation is needed and is the focus of this work. The studied cutting processes are orthogonal cutting process and nose turning process. Numerical models that simulate the chip formation process are employed to predict the chip morphology and are accompanied by machining experiments. Computed tomography is used  to scan the chips obtained from machining experiments and its ability to capture the variation in  chip morphology  is evaluated.  For nose turning process,  chip  curl parameters during the cutting process are to be calculated. Kharkevich model is utilized in this regard to calculate the  ‘chip in process’ chip curl parameters. High speed videography is used to measure the chip side flow angle during the cutting process experiments and are directly compared to physics based model predictions. The results show that the methodology developed provides  the framework where advances in numerical models can be evaluated reliably from a chip morphology prediction capability view point for nose turning process. The numerical modeling results show that the chip morphology variation for varying cutting conditions is predicted qualitatively. The results of quantitative evaluation of chip morphology prediction shows that the error in prediction is too large to be used for predictive modelling purposes.

Place, publisher, year, edition, pages
Trollhättan: University West , 2015. , p. 67
Series
Licentiate Thesis: University West ; 5
Keywords [en]
Chip curl, Chip flow, Computed tomography, Chip formation, Machining
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-8671ISBN: 978-91-87531-20-0 (print)ISBN: 978-91-87531-21-7 (print)OAI: oai:DiVA.org:hv-8671DiVA, id: diva2:871453
Presentation
2016-03-31, 11:00 (English)
Supervisors
Available from: 2016-04-01 Created: 2015-11-14 Last updated: 2019-12-03Bibliographically approved
List of papers
1. Characterization of Chip Morphology in Oblique Nose Turning employing High Speed Videography and Computed Tomography Technique
Open this publication in new window or tab >>Characterization of Chip Morphology in Oblique Nose Turning employing High Speed Videography and Computed Tomography Technique
2016 (English)In: Proceedings International Conference on competitive Manufacturing: 27 January - 29 January 2016 Stellenbosch, South Africa organised By The department Of Industrial Engineering Stellenbosch University / [ed] Dimiter Dimitrov & Gert Adriaan Oosthuize, Department of Industrial Engineering Stellenbosch University , 2016, p. 249-254Conference paper, Published paper (Refereed)
Abstract [en]

Simulation of industrial cutting processes employing physics based numerical models provide valuable insights into its deformation mechanics. Evaluating such models through chip studies require characterizing complex geometric features like chip shape, and chip curl. In this study, a characterization methodology is developed employing tools like computed tomography (CT) and high speed imaging. The methodology is used to characterize chip curl parameters such as chipside flow angle, chip up curl and chip side curl in oblique nose turning process. To evaluate the methodology, AISI 1045 steel is machined over a range of machining parameters and the chips obtained are characterized. The study shows that the employed methodology can be used to characterize varying chip curl geometries in nose turning process. CT technique is additionally employed when the chips are significantly deformed. The study also shows that the developed characterization methodology could be used to evaluate physics based numerical models.

Place, publisher, year, edition, pages
Department of Industrial Engineering Stellenbosch University, 2016
Keywords
Chip curl, high speed videography, computed tomography
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-8669 (URN)978-0-7972-1602-0 (ISBN)
Conference
International Conference on Competitive manufacturing – COMA ‘16”in Stellenbosch, South Africa 2016
Note

Ingår i licentiatuppsats

Available from: 2015-11-14 Created: 2015-11-14 Last updated: 2020-01-14Bibliographically approved
2. FE Modelling and Characterization of Chip Curl in Nose Turning process
Open this publication in new window or tab >>FE Modelling and Characterization of Chip Curl in Nose Turning process
(English)In: International Journal of Machining and Machinability of Materials, ISSN 1748-572XArticle in journal (Refereed) Submitted
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-8670 (URN)
Note

Inågr i licentiatuppsats

Available from: 2015-11-14 Created: 2015-11-14 Last updated: 2019-11-18Bibliographically approved
3. Modeling of Chip curl in Orthogonal Turning using Spiral Galaxy describing Function
Open this publication in new window or tab >>Modeling of Chip curl in Orthogonal Turning using Spiral Galaxy describing Function
2016 (English)In: Proceedings International Conference on competitive Manufacturing: 27 January - 29 January 2016 Stellenbosch, South Africa organised By The department Of Industrial Engineering Stellenbosch University / [ed] Dimiter Dimitrov & Gert Adriaan Oosthuizen, Global Competitiveness Centre in Engineering Department of Industrial Engineering Stellenbosch University , 2016, p. 33-38Conference paper, Published paper (Refereed)
Abstract [en]

With advances in modeling of machining process, a methodology for quantitative evaluation of the chip curl shape in orthogonal turning process is highly desired. To achieve this, a function to fit the varying chip curl was required. A mathematical function which is used to describe spiral galaxies is employed in this work which is able to accurately model wide variety of chip curl shapes. The function is employed to compare the chip curl predicted by numerical models with experimental investigations and it should be able to capture the variation of chip curl for varying cutting conditions ranging from tightly wound springs to comma shapes and the transition between them. This provides insights into the evaluation of cutting models from a practical view point. Finite element simulations were performed to predict the chip shape for varying tool rake angles and feed rates in orthogonal cutting process. The results show that the mathematical function was capable to model the wide variety of chip curl shapes encountered in orthogonal turning process.The chip curl predicted by the simulations show that numerical simulations need advanced models to depict work piece material behaviour, heat transfer behaviour and friction behaviour to predict the variation in chip curl shapes accurately for an orthogonal turning process.

Place, publisher, year, edition, pages
Global Competitiveness Centre in Engineering Department of Industrial Engineering Stellenbosch University, 2016
Keywords
Chip curl, machining, finite element simulation
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-8668 (URN)978-0-7972-1602-0 (ISBN)
Conference
6th International Conference on Competitive Manufacturing – COMA ‘16”in Stellenbosch, South Africa 2016
Note

Ingår i Licentiatuppsats

Available from: 2015-11-14 Created: 2015-11-14 Last updated: 2020-01-14Bibliographically approved
4. Quantitative Characterization of Chip Morphology Using Computed Tomography in Orthogonal Turning Process
Open this publication in new window or tab >>Quantitative Characterization of Chip Morphology Using Computed Tomography in Orthogonal Turning Process
2015 (English)In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 33, p. 299-304Article in journal (Refereed) Published
Abstract [en]

Abstract The simulation of machining process has been an area of active research for over two decades. To fully incorporate finite element (FE) simulations as a state of art tool design aid, there is a need for higher accuracy methodology. An area of improvement is the prediction of chip shape in FE simulations. Characterization of chip shape is therefore a necessity to validate the FE simulations with experimental investigations. The aim of this paper is to present an investigation where computed tomography (CT) is used for the characterization of the chip shape obtained from 2D orthogonal turning experiments. In this work, the CT method has been used for obtaining the full 3D representation of a machined chip. The CT method is highly advantageous for the complex curled chip shapes besides its ability to capture microscopic features on the chip like lamellae structure and surface roughness. This new methodology aids in the validation of several key parameters representing chip shape. The chip morphology’s 3D representation is obtained with the necessary accuracy which provides the ability to use chip curl as a practical validation tool for FE simulation of chip formation in practical machining operations. The study clearly states the ability of the new CT methodology to be used as a tool for the characterization of chip morphology in chip formation studies and industrial applications.

Keywords
validation, Finite lement method, Computed Tomography
National Category
Manufacturing, Surface and Joining Technology Other Mechanical Engineering
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-7888 (URN)10.1016/j.procir.2015.06.053 (DOI)2-s2.0-84939796397 (Scopus ID)
Conference
9th CIRP Conference on Intelligent Computation in Manufacturing Engineering - CIRP ICME ’14
Available from: 2015-08-13 Created: 2015-08-13 Last updated: 2019-12-02Bibliographically approved

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