Design and Development of a Pneumatic Non-explosive Quick-Stop Device for CNC Turning

Abstract

AbstractIn metal cutting, chip formation is both a fundamental and complex process. The workpiece material ahead of the cutting tool is deformed first in the primary shear zone and then in the secondary shear zone during the machining operation. The ‘chip root’ is the material included inside these two zones. A quick-stop device (QSD) is a research tool used to gather the chip-root samples. Prior to the development process, the QSD was developed to collect a frozen chip from the workpiece. The collected frozen chip needs to have minimal changes in its geometrical and metallurgical properties to reduce errors. The main objective of this research is to evaluate and analyze the performance of the newly developed pneumatic non-explosive QSD for the turning processes. QSD device was constructed to improve the machining operation which may include extending the tools’ life expectancy, helps to select the proper tools for certain workpieces, and calculate the amount of friction and heat produced. The QSD design is constructed in CATIA and then simulated using explicit dynamics and statics structural analyses using the Finite Element Method in ANSYS. The complete fabricated QSD is then tested for machinability with surface roughness as the machining output and the data is compared with the normal cutting. Chip root formation of an orthogonal cutting experiment on an AISI 316L steel shows that the newly developed QSD may produce the required results of chip root formation.KeywordsAISI 316LChip formationChip rootCNC turningMetal cuttingQuick-stop device