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Research Papers

Analytical Modeling and Experimental Validation of Cutting Forces Considering Edge Effects and Size Effects With Round Chamfered Ceramic Tools

[+] Author and Article Information
Kejia Zhuang, Jian Weng

Hubei Digital Manufacturing Key Laboratory,
School of Mechanical and
Electronic Engineering,
Wuhan University of Technology,
Wuhan 430070, China

Dahu Zhu

Hubei Key Laboratory of Advanced
Technology for Automotive Components,
Wuhan University of Technology,
Wuhan 430070, China;
Hubei Collaborative Innovation Center for
Automotive Components Technology,
Wuhan University of Technology,
Wuhan 430070, China
e-mail: dhzhu@whut.edu.cn

Han Ding

Hubei Digital Manufacturing Key Laboratory,
School of Mechanical and
Electronic Engineering,
Wuhan University of Technology,
Wuhan 430070, China;
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of Science and Technology,
Wuhan 430074, China

1Corresponding author.

Manuscript received November 12, 2017; final manuscript received April 6, 2018; published online June 4, 2018. Assoc. Editor: Guillaume Fromentin.

J. Manuf. Sci. Eng 140(8), 081012 (Jun 04, 2018) (16 pages) Paper No: MANU-17-1704; doi: 10.1115/1.4040087 History: Received November 12, 2017; Revised April 06, 2018

The cutting force is one of the key factors for planning and optimizing the machining operation in material removal processes. An analytical cutting force prediction model that takes into consideration both edge effects and size effects based on the oblique cutting theory is developed and analyzed in this study. A detailed analysis of the cutting geometry is presented based on the coordinate system transformation and uncut chip thickness (UCT), which is evaluated on the rake plane instead of the reference plane. Then, the developed Johnson–Cook constitutive model of the workpiece that takes into consideration the size effects is then applied to the prediction of edge forces coefficients and cutting forces coefficients. The edge forces are predicted using the edge coefficients prediction model with the regularity found in the orthogonal simulations, which reflect the influences of chamfered length and chamfered angle. The developed model is validated using the turning operations of super alloys with round chamfered inserts. Finally, the effects of the cutter edge, cutting parameters, and UCT on the cutting forces are investigated using the developed model. The reasonableness and effectiveness of the proposed model is demonstrated through the comparison of the measured and predicted cutting forces for various chamfer characteristics.

Copyright © 2018 by ASME
Topics: Cutting
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Figures

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Fig. 1

Cutting geometry analysis of turning with round inserts: (a) schematic of turning operation, (b) oblique cutting theory, (c) contact area of round inserts, (d) round insert, and (e) cutting with chamfered edge

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Fig. 2

Discretization of the immersion part of the round inserts in the view of rake face plane

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Fig. 3

Uncut chip thickness and shear stress with respect to the immersion angle of round inserts

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Fig. 4

Round cutting insert and schematic diagram of the chamfered edge

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Fig. 5

Round cutting insert and schematic diagram of the chamfered edge

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Fig. 6

Orthogonal simulations with different cutting edge characteristics by AdvantEdge: (a) different chamfered lengths and (b) different chamfered angles

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Fig. 7

Cutting force versus chamfered angle

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Fig. 8

Cutting force versus chamfered length

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Fig. 9

Experimental setup for high speed turning of super alloys

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Fig. 10

Comparison of the measured and predicted cutting forces of Ti6Al4V

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Fig. 11

Comparison of the measured and predicted cutting forces for Inconel 718

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Fig. 12

Cutting forces with respect to cutting depth in turning of Inconel 718

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Fig. 13

Cutting forces with respect to feed rate in turning of Inconel 718

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Fig. 14

Diagrams of simulations for various UCT

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Fig. 15

Feeding and back resistance forces with respect to UCT from simulations of turning Inconel 718

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Fig. 16

Three components of cutting forces for round inserts in turning of Inconel 718

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Fig. 17

Cutting forces with respect to edge characteristics in turning of Inconel 718

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