The Influence of Cutting Parameters on Plastic Deformation and Chip Compression during the Turning of C45 Medium Carbon Steel and 62SiMnCr4 Tool Steel (original) (raw)
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Journal of Manufacturing Processes, 2020
One of the important phenomena of orthogonal cutting process is the occurrence of the minimum uncut chip thickness, as its highly affects the process of cutting initiation and surface roughness. But nowadays non orthogonal i.e., oblique cutting process using special tools with continued cutting edge and high value of cutting angle λ s make new possibilities in the field of research. Hence, this paper presents the results of such analyzes and investigations of oblique cutting impact using tool with λ s € < angle < 0°, 60°> on the minimum uncut chip thickness during free-radial turning of C45 steel using sintered carbide edges S3OS with r n = 18, 28, 90 μm, respectively. The results show that the experimentally determined minimum uncut chip thickness decreases with the increase of the value of the λ s angle and in accordance with the derived theoretical Equations concerning the direction of the chip flow. Moreover, it establishes the possibility of significantly lowering the h min value with the increase of the absolute value of the angle λ s and it opens a new directions of tool edges for oblique cutting to finish machining and sheds new light on abrasive wear issues, during which micro-cutting may occur.
International Journal of Engineering Research and Technology (IJERT), 2014
https://www.ijert.org/a-study-on-effect-of-basic-cutting-variables-on-machining-characterestics-of-low-carbon-steel-work-material-in-turning https://www.ijert.org/research/a-study-on-effect-of-basic-cutting-variables-on-machining-characterestics-of-low-carbon-steel-work-material-in-turning-IJERTV3IS080566.pdf Machining is the most versatile manufacturing process and is influenced by a number of cutting parameters. The selection of parameters values for optimum result and maximizing material removal rate is crucial in realizing economy in manufacturing. The present work is aimed to establish the influence of feed, depth of cut and cutting speed on cutting characteristics of a standard work-material like Low Carbon steel under dry and wet conditions of machining. Using the cutting force data, an empirical model for power component of cutting force was developed. The goodness of fit of the model with the data was also tested. The surface roughness measurement indicates better surface finish with smaller feed magnitude and increased magnitudes of cutting speed. The application of cutting fluid improves surface finish. The specific power consumption decreases with increase in feed values, but shows a rising trend with high values of cutting speed indicative of ineffectiveness of cutting fluid at high speeds.
CHIP DEFORMATION AND ITS MORPHOLOGY IN ORTHOGONAL CUTTING OF HARDENED STEEL 42CrMo4
2010
The chip formation and morphology are definitely affected by tool geometry and cutting parameters such as cutting speed (v), feed rate (s), and depth of cutting (a). An experiment investigation was presented to study the influence of tool geometry on chip morphology and chip deformation in orthogonal turning. The experiment is realized with the lathe machine IK62. For data process is used a statistic method with five factors. The result obtained in this study showed that tool geometry
Chip Formation and Coefficient of Friction in Turning S45C Medium Carbon Steel
International Journal of Mechanical & Mechatronics Engineering
This paper presents the tribology issue regarding the chip formation in machining medium carbon steel (S45C) using coated and uncoated carbide tool. The machining parameters under investigation were cutting speed, feed rate, and depth of cut under dry cutting condition using coated and uncoated carbide tools. The chip shape was largely depends on the combination of machining parameters especially at high depth of cut, the favorable chips was produced. Smaller value of coefficient of friction indicates that the shear angle is larger which results in smaller shear plane area that provides benefits of lower cutting force needed to shear off the chips and lower cutting temperature being generated during the machining process. Index Term— medium carbon steel (S45C), turning process, chip formation, carbide tools I. INTRODUCTION THE chip formation is a result of tearing or pulling rather than cutting, which will affect the tool life, surface finish, and workpiece accuracy. An in depth und...
imtuoradea.ro
This paper describes a study concerning the influence of plastic deformations on the cutting zone at the plain turning with small cutting feeds. It notes that in the field of cutting feeds, the real roughness is much greater than the geometric roughness because of high plastic deformations that appear in the cutting zone. The determined coefficients are parameters which evaluate the deformability in the cutting area, therefore allow the establishment of material machinability in the small cutting feeds.
Research on Chip Shear Angle and Built-Up Edge of Slow-Rate Machining EN C45 and EN 16MnCr5 Steels
Metals
One of the phenomena that accompanies metal cutting is extensive plastic deformation and fracture. The excess material is plastically deformed, fractured, and removed from the workpiece in the form of chips, the formation of which depends on the type of crack and their propagation. Even in case of the so-called ‘continuous’ chip formation there still has to be a fracture, as the cutting process involves the separation of a chip from the workpiece. Controlling the chip separation and its patterning in a suitable form is the most important problem of the current industrial processes, which should be highly automated to achieve maximal production efficiency. The article deals with the chip root evaluation of two EN C45 and EN 16MnCr5 steels, focusing on the shear angle measuring and built-up edge observation as important factors influencing the machining process, because a repeated formation and dislodgement of built-up edge unfavorably affects changes in the rake angle, causing fluctu...
Sinergi, 2020
In the machining of metal cutting, cutting tools are the main things that must be considered. Using improper cutting parameters can cause damage to the cutting tool. The damage is Built-Up Edge (BUE). The situation is undesirable in the metal cutting process because it can interfere with machining, and the surface roughness value of the workpiece becomes higher. This study aimed to determine the effect of cutting speed on BUE that occurred and the cutting strength caused. Five cutting speed variants are used. Observation of the BUE process is done visually, whereas to determine the size of BUE using a digital microscope. If a cutting tool occurs BUE, then the cutting process is stopped, and measurements are made. This study uses variations in cutting speed consisting of cutting speed 141, 142, 148, 157, 163, and 169 m/min, and depth of cut 0.4 mm. From the results of the study were obtained that the biggest feeding force is at cutting speed 141 m/min at 347 N, and the largest cutting force value is 239 N with the dimension of BUE length: 1.56 mm, width: 1.35 mm, high: 0.56mm.
International Journal of Engineering Research and Technology (IJERT), 2015
https://www.ijert.org/modeling-and-analysis-of-effect-of-cutting-parameters-on-product-quality-in-dry-turning-operation-of-mild-steel-using-carbide-high-speed-steel-tool https://www.ijert.org/research/modeling-and-analysis-of-effect-of-cutting-parameters-on-product-quality-in-dry-turning-operation-of-mild-steel-using-carbide-high-speed-steel-tool-IJERTV4IS080368.pdf Material removal plays an important role in finishing part/components. Information about cutting forces during machining can be considered as an index to evaluate the machinability of a material while considering the amount of heat in the cutting area, tool wear, quality of machined surface and accuracy of the part. In the present study, an attempt has been made to investigate the effect of cutting parameters (cutting speed, feed rate and depth of cut) on cutting forces (feed force, thrust force) and surface roughness for turning of mild steel using high speed steel (HSS) and carbide tool. Experiments were conducted on a precision lathe (HMT) and the influence of cutting parameters was studied using analysis of variance (ANOVA) based on adjusted approach. The results showed that with increasing the depth of cut and feed for a given RPM, cutting force increases. With the same cutting speed and depth of cut, the force variation is significant in both high speed steel (HSS) and carbide tool. The minimum cutting force requirement for machining the component (theoretically) is almost same with that of experimental value obtained by dynamometer.
King Mongkut’s University of Technology North Bangkok International Journal of Applied Science and Technology, 2013
The influence of cutting parameters viz. cutting speed, feed rate and depth of cut, tool geometry viz. rake angle, clearance angle and nose radius on turning of AISI 304 stainless steel, AISI 52100 bearing steel and AISI D2 tool steel with advanced cutting tools like multicoated carbide, cermet and alumina inserts are investigated experimentally. The machining performance (i.e. output parameters) considered in this article are surface roughness, flank wear and tool-shim interface temperature. Experiments are conducted according to Taguchi’s orthogonal array and ANOVA is performed to evaluate the significance of each of the input parameters on each of the output parameters. It is found that variation in work materials, and tool materials have significant effect on flank wear apart from cutting speed. Tool cutting edge geometry like nose radius and clearance angle influenced surface roughness apart from the cutting parameters. Variations in work material, cutting fluids and nose radiu...