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Analysis of entry phase in intermittent machining
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0003-3876-2361
2018 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Cutting forces and vibrations are essential parameters in the assessment of a cutting process. As the energy consumption in the machining process is directly affected by the magnitude of the cutting forces it is of vital importance to design cutting edges and select process conditions that will maintain high tool performance through reduced energy consumption. The vibrations are often the cause of poor results in terms of accuracy, low reliability due to sudden failures and bad environmental conditions caused by noise. The goal of this work is to find out how the cutting edge and cutting conditions affect the entry conditions of the machining operation. This is done utilizing experimental methods and appropriate theoretical approaches applied to the cutting forces and vibrations. The research was carried out through three main studies beginning with a force build-up analysis of the cutting edge entry into the workpiece in intermittent turning. This was followed by a second study, concentrated on modelling of the entry phase which has been explored through experiments and theory developed in the first study. The third part was focused on the influence of the radial depth of cut upon the entry of cutting edge into the workpiece in a face milling application. The methodology for the identification of unfavourable cutting conditions is also explained herein. Important insights into the force build-up process help addressing the correlation between the cutting geometries and the rise time of the cutting force. The influence of the nose radius for a given cutting tool and workpiece configuration during the initial entry is revealed. The critical angle i.e. the position of the face milling cutter that results in unfavourable entry conditions has been explained emphasizing the importance of the selection of cutting conditions. Finally, the theoretical methods utilized for the evaluation of the role of cutting edge geometry within entry phase dynamics has been explored. This has revealed the trends that are of interest for selection of cutting conditions and cutting edge design.

Place, publisher, year, edition, pages
Trollhättan: University West , 2018. , p. 74
Series
Licentiate Thesis: University West ; 21
Keywords [en]
Entry; Cutting force; Cutting edge geometry; Acceleration
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-12255ISBN: 978-91-87531-80-4 (print)ISBN: 978-91-87531-79-8 (electronic)OAI: oai:DiVA.org:hv-12255DiVA, id: diva2:1198120
Presentation
2018-04-19, 10:00 (English)
Supervisors
Available from: 2018-04-19 Created: 2018-04-16
List of papers
1. Influence of cutting edge geometry on force build-up process in intermittent turning
Open this publication in new window or tab >>Influence of cutting edge geometry on force build-up process in intermittent turning
2016 (English)In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 46, p. 364-367Article in journal (Refereed) Published
Abstract [en]

In the intermittent turning and milling processes, during the entry phase the cutting edges are subjected to high impact loads that can give rise to dynamical and strength issues which in general cause tool life reduction. In this study the effect of geometrical features of the cutting tool on the force generation during the entry phase is investigated. Cutting forces are measured by a stiff dynamometer at a high sampling frequency. In addition, the chip load area is analyzed and related to the measured cutting force. The results show that micro-geometrical features, in particular the protection chamfer, significantly affect the force generation during the entry phase.

Place, publisher, year, edition, pages
Elsevier, 2016
Keywords
Cutting, force, edge, chip, turning, dynamic
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-9324 (URN)10.1016/j.procir.2016.04.013 (DOI)2-s2.0-84978786104 (Scopus ID)
Conference
7th HPC 2016 – CIRP Conference on High Performance Cutting, Chemnitz, Germany, May 31-June 2, 2016
Available from: 2016-04-25 Created: 2016-04-25 Last updated: 2018-04-16Bibliographically approved
2. Modeling of Force Build-up Process and Optimization of Tool Geometry when Intermittent Turning
Open this publication in new window or tab >>Modeling of Force Build-up Process and Optimization of Tool Geometry when Intermittent Turning
2017 (English)In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 58, p. 393-398Article in journal (Refereed) Published
Abstract [en]

Intermittent turning the slotted workpieces is always accompanied with a high impact load of the machine tool during the entry phase of the cutting edge. The process leads to a strong dynamic response of the system and results in vibrations arose and potential tool life and surface finish issues. The present study addresses the modeling of cutting force build-up process with further optimization of cutting edge geometry where tooltip overshoot during the tool entry is selected as an objective function. The model takes into consideration the interaction between three units of the machine tool such as a tool, toolpost, and workpiece as well as an influence of the process on the system's dynamics.

Keywords
Intermittent machining, force buid-up, optimization, cutting edge geometry, dynamic response
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-12254 (URN)10.1016/j.procir.2017.03.241 (DOI)
Conference
16th CIRP Conference on Modelling of Machining Operations (16th CIRP CMMO)
Available from: 2018-04-16 Created: 2018-04-16 Last updated: 2018-04-16Bibliographically approved
3. Influence of radial depth of cut on entry conditions and dynamics in face milling application
Open this publication in new window or tab >>Influence of radial depth of cut on entry conditions and dynamics in face milling application
Show others...
2017 (English)In: Journal of Superhard Materials, ISSN 1063-4576, Vol. 39, no 4, p. 259-270Article in journal (Refereed) Published
Abstract [en]

The choice of milling cutter geometry and appropriate cutting data for certain milling application is of vital importance for successful machining results. Unfavorable selection of cutting conditions might give rise to high load impacts that cause severe cutting edge damage. Under some circumstances the radial depth of cut in combination with milling cutter geometry might give unfavorable entry conditions in terms of cutting forces and vibration amplitudes. This phenomenon is originated from the geometrical features that affect the rise time of the cutting edge engagement into workpiece at different radial depths of cut. As the radial depth of cut is often an important parameter, particularly when machining difficult-to-cut materials, it is important to explore the driving mechanism behind vibrations generation. In this study, acceleration of the workpiece is measured for different radial depths of cut and cutting edge geometries. The influence of the radial depth of cut on the dynamical behavior is evaluated in time and frequency domains. The results for different radial depths of cut and cutting geometries are quantified using the root mean square value of acceleration. The outcome of this research study can be used both for the better cutting data recommendations and improved tool design.

Place, publisher, year, edition, pages
New York: Allerton Press, 2017
Keywords
milling entry, radial depth, cutting edge, cutting force, vibration
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-11769 (URN)10.3103/S1063457617040062 (DOI)000409936100006 ()2-s2.0-85029210912 (Scopus ID)
Available from: 2017-10-20 Created: 2017-10-20 Last updated: 2018-08-09Bibliographically approved

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