Cutting Force Values Research Articles

The Effect of Milling Parameters of Vanadis 4 Extra Steel on Cutting Force Values and Roughness of Machined Surface

The Effect of Milling Parameters of Vanadis 4 Extra Steel on Cutting Force Values and Roughness of Machined Surface

The Effect of Differences in Fiber Sizes on the Cutting Force During the Drilling Process of Natural Fiber-Reinforced Polymer Composites

This experiment aimed to analyze the impact of different fiber sizes on cutting forces during the drilling of Natural Fiber-Reinforced Polymer Composites (NFRPC) while also evaluating surface quality attributes, including delamination, fiber pullout, and overhanging fibers, influenced by variations in coconut fiber dimensions within the NFRPC material. The manufacturing process for composite panels utilized various methods, including hand layup for 200 mm long coconut fibers and composite casting for shorter fibers (2, 4, and 6 mm) mixed with polymer-epoxy. The results indicate that panels made from NFRPC with continuous fiber lengths of 200 mm exhibit higher cutting force values (253,650 N) compared to epoxy panels without fibers (235,288 N), suggesting that a significant force is required to sever the continuous fibers within the NFRPC. Conversely, the incorporation of short coconut fibers measuring 2, 4, and 6 mm reduces the cutting forces on the composite panels. However, excessive surface roughness in the final hole quality can be detrimental, primarily due to issues of delamination and fiber pull-out.

Tool wear mathematical model of PCD during ultrasonic elliptic vibration cutting SiCp/Al composite

To better cutting the SiCp/Al composite material, it is necessary to accurately predict the tool wear state of the ultrasonic elliptic vibration cutting (UEVC) process. The main cutting force is one of the key output variables to evaluate the machining performance and the tool wear process. Therefore, based on the main cutting force, tool wear strength and tool wear mechanism, the relationship between the ratio of main cutting force and cutting yield strength and cutting wear are studied to find the optimal cutting temperature range of the minimum tool wear of SiCp/Al composite. Firstly, the tool wear experiments of UEVC SiCp/Al composite at different cutting speeds are conducted. Based on the analysis of the tool wear morphology, the tool wear mechanism is discussed, and the cutting temperature and the main cutting force value at different cutting speeds are measured. Then, the mathematical model of SiCp/Al composite is considering the characteristics of SiCp/Al composite. Finally, the optimal cutting temperature range is obtained based on this mathematical model. Furthermore, the accuracy of the mathematical model is verified by the tool wear experiment, and the best cutting temperature range is consistent with the prediction results.

Shape design optimization of a flat endmill tool

AbstractAmong the many possible metal‐cutting processes, milling is regarded as one of the most widely applied processes to machine different engineering materials productively. During the milling process, there is relative motion between the endmill tool and the workpiece. Energy is required to drive the cutting force used by the tool in separating the chips from the workpiece. Several studies have focused on the effects of milling process parameters on the cutting force, for instance by varying the cutting parameters, machining properties and the extent of cooling/lubrication. Other studies have explored the influence of tool geometry and material properties on the cutting force. Results from these studies have brought about improvements in the design of milling machinery and tools. The current study presents a novel automated approach for tool geometry optimization which is fully coded in Matlab. An automated and parametrized endmill design procedure was created featuring input parameters such as rake angle, relief angle, clearance angle and helix angle, all of which have been shown, through numerous studies, to influence cutting forces. The parameters were here used to generate the shape profile for one cutting edge of a flat endmill. This cutting edge profile is next copied and rotated, as per the design's pitch angle, to form the complete set of cutting flutes for the flat endmill. Next, the surface defined by the completed profile is meshed using quadrilateral elements. The 3D endmill design is then formed by extruding, and twisting as per the helix angle, this quadrilateral mesh to form a solid hexahedral mesh. Finally, an automated iterative optimization process was defined, featuring the above parametrized design process coupled with Abaqus‐based finite element simulation of the milling process. The expected result is that the proposed optimization procedure will be able to identify the endmill design parameters which minimize the cutting force. At the completion of the optimization, a minimized maximum resultant cutting force value is obtained from using the newly optimized endmill. The resultant cutting force was reduced by 17.6%. It is anticipated that the automated design, meshing and simulation‐driven optimization approach is generalizable to other tool design variations.

Influences of size effect and workpiece temperature during cryogenic micro milling of soft viscoelastic polymer: an experimental assessment

Application of tool-based micromachining in soft polymer has been limited due to high adhesion and low elastic modulus of this material at room temperature. This study aims to evaluate the machinability of a typical viscoelastic soft polymer and understand the effect of material and process parameters on machining performances. In this study, a micro-milling process using cryogenic-assisted cooling is proposed and the importance of temperature control toward glass transition zone was particularly addressed. To identify insight of machinability in micro domain, this article also determines minimum uncut chip thickness (MUCT) and size effects by considering the variations of cutting force and surface integrity with the ratio of h/re (uncut chip thickness (h) to cutting edge radius (re)). The experimental results reveal that consideration of size effect during micromilling of soft viscoelastic polymer helps in reduction of machined surface roughness (Sa) value. Based on the cutting force pattern, it is evaluated that higher machining stability can be achieved during cryogenic machining by reduction of specific cutting force value. Moreover, temperature range around glass transition zone yields more promising experimental outcomes, outperforming other cooling zones.

The Effect of Phytogenic Additive in Broiler's Diet on Production Results, Physicochemical Parameters, and the Composition of Volatile Organic Compounds of Broiler Meat Assessed by an Electronic Nose System.

The primary objective of this study was to investigate the impact of a phytogenic additive (PA) in broiler chickens' diet on production, physiochemical parameters, and the profile of volatile organic compounds present in broiler chickens' meat. The experiment was conducted in a commercial chicken house, where Ross 308 broiler chickens were divided into two groups, each consisting of 65,000 broilers. One group was fed a diet supplemented with 100 ppm of PA throughout the rearing period. The primary chemical composition of the meat and its physicochemical parameters were determined. A visual assessment of breast muscles for defects and volatile organic compounds were evaluated using an electronic nose system. No statistically significant differences were shown in the production performance of the chickens; while summarizing all production parameters, a higher EPEF index of 31 points in the experimental group was highlighted. Breast muscle quality showed differences in drip loss and WHC (p ≤ 0.01) in favor of the experimental group, and a lower cutting force value (p ≤ 0.05) was found for breast muscles from the experimental group. The group also had a lower proportion of muscles with a white striping defect, and the results of volatile organic compound profiling showed the most aroma units.

Optimization of cutting parameters using response surface methodology (RSM) in milling Inconel 718 superalloy using Borax-added nanofluid in (MQL) system

PurposeThe need for materials with superior mechanical and physical properties has recently increased. Inconel 718, one of these superalloys, is frequently used in the aviation and space industry. However, during Inconel 718 superalloy machining, cutting tools and cutting fluid were excessively consumed. This study aims to investigate using an innovative and environmentally friendly cutting fluid in milling the Inconel 718 superalloy.Design/methodology/approachIn this study, a Borax- (BX-)added cutting nanofluid was prepared and used for the first time as a coolant in the minimum quantity lubrication (MQL) system of Inconel 718’s face milling process. Response surface methodology (RSM) was used to determine the effect of the BX element on cutting performance. Face milling operations were carried out by adding BX elements at 1.5% and 3% at two different rates.FindingsAs the BX additive ratio in the cutting fluid used in the MQL system increased, the cutting force values decreased. The lowest cutting force value was measured in the tests with cutting fluid containing 1.5% BX. In addition, a smoother surface was obtained by adding 1.5% BX to the cutting fluid. Furthermore, cutting tool life increased by 20% compared to 0% by 3% BX nanofluid concentration.Originality/valueThe study is innovative regarding the material processed, the cutting fluid used and the method used for the aerospace industry.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0191/

Effects of Storage Duration and Temperature on Browning and Quality of Postharvest Bamboo Shoots

Due to the high respiration rate and ethylene production at the cut surface of bamboo (Dendrocalamus latifloxus Munro) shoots after harvesting, browning and lignification at the cut surface reduce their quality and shelf life. Due to the demand of consumers, using physical treatment to inhibit microbial growth and maintain quality has become more and more popular. In this study, bamboo shoots were treated with hot water at 70 °C for 30 s after harvesting and then stored at 1, 3, or 5 °C for 4 weeks to measure the quality change. Our results show that the L* value and h° angle at the cut surface of the bamboo shoots were significantly higher, but the respiration rate was significantly lower when stored at 1 °C compared with those at 3 and 5 °C. In terms of quality, the bamboo shoots showed lower firmness and cutting force values, and no decay was observed at 1 °C. The results from the shelf simulation test with rewarming of the cold-treated bamboo shoots at ambient temperature (25 °C) for 1 day indicated that the L* value and h° angle were significantly higher for the bamboo shoots stored at 1 °C compared with those stored at 3 and 5 °C. Taken together, browning and lignification at the cut surface were effectively inhibited, quality was maintained, and the storage life could be extended to 4 weeks at 1 °C.

Impact of Cutting Data on Cutting Forces, Surface Roughness, and Chip Type in Order to Improve the Tool Operation Reliability in Sintered Cobalt Turning.

The authors present the results of laboratory tests analysing the impact of selected cutting data and tool geometry on surface quality, chip type and cutting forces in the process of orthogonal turning of sintered cobalt. The selected cutting data are cutting speed and feed rate. During the experiments, the cutting speed was varied in the range of vc = 50-200 m/min and the feed rate in the range of f = 0.077-0.173 mm/rev. In order to measure and acquire cutting force values, a measuring setup was assembled. It consisted of a Kistler 2825A-02 piezoelectric dynamometer with a single-position tool holder, a Kistler 5070 signal amplifier and a PC with DynoWare software (Version 2825A, Kistler Group, Winterthur, Switzerland)). The measured surface quality parameters were Ra and Rz. The components of the cutting forces obtained in the experiment varied depending on the feed rate and cutting speed. The obtained test results will make it possible to determine the optimal parameters for machining and tool geometry in order to reduce the machine operating time and increase the life of the cutting insert during the turning of sintered cobalt, which will contribute to sustainable technology.

Development of cutting force components in high-speed cutting on turning centre

The article deals with the investigation of high-speed cutting. The influence of cutting speed on the development of individual cutting force components in turning was determined. Cutting tests were carried out on turning centre during the machining of C45 medium carbon steel material. The cutting tool material was cubic boron nitride. Cutting speed was selected with respect to the high-speed cutting (HSC) based on previous studies. In the experiment, cutting force components were recorded. From the results, a decreasing trend in the cutting force values was observed from the cutting speed higher than 1100 m.min-1. It can be caused by changing of metallurgical and mechanical properties in the cutting zone because the overall cutting resistance during HSC was reduced. Chips changed colour to orange during the machining due to temperature changes. No great benefit was observed when high-speed cutting for turning medium carbon steel material. The inefficiency, in this case, is caused by the high price and low tool life of the CBN cutting inserts as well as the cutting force that decreases slowly after the initial increase with a rapidly increasing cutting speed.

Physics-guided intelligent system for cutting force estimation in ultrasonic atomization-assisted micro-milling of porous titanium

Porous titanium is a new biomechanical implant material due to the good mechanical properties and biocompatibility. In order to meet the manufacturing needs of anisotropic porous titanium with complex micro-structures, the ultrasonic atomization with excellent cooling and lubrication effect is integrated with the micro-milling operation. Accurate prediction of cutting forces in the machining process is a principal factor as it exerts indispensable influence on the process efficiency and surface integrity. The prediction power of the traditional physics-based mechanistic cutting force model has been limited by the explicit relationship between force components and process variables based on the cutting mechanism and process geometries. In this paper, a comprehensive physics-guided intelligent system for stochastic cutting forces estimation is developed in the ultrasonic atomization-assisted micro-milling operation of porous titanium. The physics-based mechanistic cutting force model is proposed based on the determination of in-process random porosity of machined porous titanium with tool-workpiece contact. The influence of process uncertainty related to size effect and tool run-out is considered in the proposed physics-based mechanistic model. To overcome the poor nonlinear fitting and indeterminate cutting constants with numerous experiments, the machine learning algorithm has been merged into the physics-based mechanistic model to establish the physics-guided intelligent system of stochastic cutting force prediction. The predicted cutting force values of the proposed comprehensive physics-guided machine learning system are validated by the measured results with a wide variety of ultrasonic atomization-assisted micro-milling tests.

Investigation on carbon fiber fracture mechanism of honeycomb composites in longitudinal‐torsional ultrasonic‐assisted milling processes

AbstractA multi‐edge micro‐tooth longitudinal‐torsional ultrasonic‐assisted milling (LTUAM) model was established based on the hard brittle characteristics of carbon fiber honeycomb composites and the weak strength characteristics of the hole wall interface. The study analyzed the effects of ultrasonic characterization parameters on the cutting force, honeycomb wall width, and surface morphology. The results indicate that using LTUAM significantly reduced the cutting force and decreased the length and height of the burrs at an appropriate ultrasound amplitude. The spindle speed had the least impact on the width of the honeycomb wall, but increased with the longitudinal‐torsional ultrasonic amplitude and feed rate. The maximum error between the simulated and experimental cutting force values was approximately 19%. The longitudinal amplitude and torsional amplitude were 3 and 5 μm, respectively, the length of burrs decreased by 52.7%, and there was less delamination and tearing damage. LTUAM proved to be beneficial in improving cutting performance. Compared with conventional milling (CM), LTUAM resulted in regular fiber fracture morphology and smaller fragments on the honeycomb surface. In addition, the high‐frequency ultrasonic vibration promoted carbon fiber fracture and the surface roughness value under LTUAM was approximately 36.72% smaller than that of CM.Highlights Ultrasonic milling mechanism of carbon honeycomb is studied. Kinematic simulation of the tool of carbon honeycomb was studied during LTUAM. LTUAM promotes the fracture of carbon fibers. A multi‐edge micro‐tooth LTUAM model was established of carbon honeycomb. Deformation of the cell wall can be avoided by ultrasonic vibration of the cutter.

Machining fiber-reinforced glass-epoxy composites with cryo-treated and untreated HSS cutting tools of varying geometries

Depending on the expanding application areas of glass fiber reinforced composite materials, quality machining of such materials also receives increasing interest. However, since the cutting tools used for machining such composites generally have standard geometric properties, both the life of the cutting tool and the quality of the machined composite workpiece are adversely affected by. In this study, the performance and the most optimum drilling geometries of untreated (UT) and cryo-treated&tempered (DCT&T) HSS cutting tools used for machining of fiber-reinforced glass-epoxy composites were investigated. Moreover, Taguchi experimental design was employed to reduce the number of experiments, and also the analysis of variance (ANOVA) and regression analysis were performed. Furthermore, XRD analysis and microhardness tests were applied to UT and DCT&T HSS cutting tools. From the highest and lowest delamination factor (Fd) values obtained using UT and DCT&T HSS drills, it was understood that DCT&T HSS drills achieved better results by 0.8% and 0.7%, respectively. According to average surface roughness (Ra) values obtained, the performances of DCT&T HSS drills were 14.76% (for the highest Ra value) and 2.69% (for the lowest Ra value), better than UT HSS drills. When the highest and lowest cutting force values were compared, it was seen that the cutting force values obtained using DCT&T HSS drills were 24.54% and 16.15% less than the cutting force values obtained using UT HSS drills, respectively. According to the S/N ratios for the cutting forces, the most optimum geometries of the cutting tool were found to be 128° point angle, 33° helix angle and 8° clearance angle, respectively. With respect to S/N ratios for Fd values, the most optimum geometries of the cutting tool were found to be 118° point angle, 26° helix angle and 8° clearance angle, respectively. Based on S/N ratios for Ra values, the most optimum geometries of the cutting tool were found to be 128° point angle, 26° helix angle and 8° clearance angle, respectively. On the other hand, as a result of the regression analysis, R2 values obtained over 90% show that the regression models are quite successful. Besides, it was observed (from SEM and thermal camera images) that the epoxy resins in the chips produced at high spindle speeds melted because of high temperature, which indicated that the integrity of the composite workpieces started to deteriorate.

Influence of hBN nanofluid MQL on machining characteristics in turning of Inconel 625

Inconel 625 has a major component of nickel and chromium alloying elements. It is used in turbines and propeller shafts in aircraft engines. This study examines the impact of force, roughness, and wear mechanisms during the MQL-machining of Inconel 625 on the wt.% of nanofluids, cutting velocity, and feed rate. The experiments are carried out using an L20 orthogonal array. The cutting insert is PVD (TiAlN), and the nanofluid is hexagonal boron nitride mixed with the coconut oil. The findings indicated that low feed, low hBN concentration, and high turning speed resulted in a reduced cutting force value. A greater concentration value indicated a lower surface roughness, whereas increased speed and feed increased roughness. Based on analysis of optical micrograph, abrasion and adhesion wear are two modes of wear mechanisms.

Investigation of Cutting Performance of Nano/Layered Hard Coatings in Face Milling of AISI D2 Steel

In the die-molding industry, milling steels in a hardened condition is common. Tool wear and cutting-forces occurring during this process must be considered for better surface quality. The cutting performance of nano-layered AlTiN/TiN coated carbide cutting-tools in AISI D2 face-milling was evaluated in this work. Single-layer hard-coated carbide cutting-tools and uncoated cutting-tools were used to compare cutting performance testing. All cutting-speeds nano-layer AlTiN/TiN coated carbide cutting tool presented longer cutting-length than TiAlN and TiN coated ones and uncoated tool. Notch wear is an overriding wear mechanism, followed by build-up edge formation for all cutting-tools. Using a nano-layer AlTiN / TiN hard-coating, cutting-force values were lowered in all experiments.

Investigation of the Cutting Fluid Incidence Angle Direction in Turning Grade 5 ELI Titanium Alloy under High-Pressure Cooling Conditions.

The use of high-pressure cooling (HPC) in machining can increase the efficiency and improve process stability through more effective breaking and chip evacuation. Turning tests of the Grade 5 ELI titanium alloy were carried out using cemented carbide tools and taking into account the direction of feeding of the cutting liquid. Measurements of the components of the total cutting force were carried out for feeds in the range f = <0.08; 0.13> mm/rev and two angular settings (i.e., angle α = <30°; 90°> and β = <0°; 60°>) of the nozzle. The chip breakage coefficient was determined. It was shown that the cutting force values depended on the feed value, and the angle of feeding of the cutting fluid did not significantly affect the values of the cutting forces. Despite the different forms of chips obtained, the applied method of searching for the best conditions was unsuccessful and no significant effect on the values of the chip breaking coefficient Cch was observed. To determine the best nozzle setting, it is useful to determine the working area of the chip breaker. Due to the shape of the chip, the optimal angular setting for the nozzle that supplied the cutting fluid was α = 60° and β = 30°. In addition, it was observed that the angle of incidence of the cutting fluid jet could affect the chip formation process and support the chip cracking process.

Parametric Optimization of Cutting Force and Temperature in Finite Element Milling of AISI P20 Steel

Multiple manufacturing methods are used in the manufacturing industry. The most commonly used method is machining methods. With machining methods, production can be made from both raw materials and finishing processes can be applied to products produced with different production methods. However, the initial cost of machining operations is quite high due to factors such as the machining parameters used during the process, the rigidity of the machine, and the machining conditions. Today, the finite element method (FEM) has been widely used in order to reduce the initial cost of machining. For this reason, in our study, the machining of AISIP20 material was carried out with the FEM. This study, four different cutting speeds, feed rates and two different cutting depths were used and the lateral feed rate was kept constant. As a result of the study, the cutting force values and temperature values that occurred depending on the machining parameters were evaluated by finite element analysis. Consequently, in the study, an increase in the cutting force occurred in general with the increase of feed, cutting depth and cutting speed parameters, and a decrease in temperature values occurred with an increase in cutting speed and feed and constant cutting depth. The lowest cutting force was 36.11 N, while the highest was 1951.42 N. The lowest and highest temperature values that occur during the process are 448.98 and 593.14 °C, respectively. In this regard, for the optimization of the parameters, the proportional change between the parameters and the finite elements as well as the physical processes can be performed for the desired final product.

Development and testing of a stationary dynamometer using cross-beam-type force-sensing elements for three-axis cutting force measurement in milling operations

This study focused on the development and testing of a stationary dynamometer using force-sensing elements capable of measuring three axes of cutting force during milling operations. The force-sensing element was based on the Maltese cross-beam concept but has been improved and modified to increase sensitivity and reduce interference or cross-talk error. A Finite element analysis was conducted to study strain distribution and determine sensor positions in the force-sensing element. By using four force-sensing elements and several piezoresistive strain sensors, a stationary dynamometer prototype was constructed. A series of calibration tests were performed to evaluate the dynamometer’s sensitivity, linearity, hysteresis, and repeatability over three orthogonal axes. The dynamometer’s dynamic features and functionality for milling applications were examined through modal analysis and real milling tests. Additionally, the end-milling and slot-milling cutting force values were compared to those of a reference dynamometer (Kistler 9129AA). Overall, the experimental results indicated that the proposed stationary dynamometer is a reliable and accurate alternative for measuring cutting force during machining operations and other force measurements.

Comparative Analysis of Minimum Chip Thickness, Surface Quality and Burr Formation in Micro-Milling of Wrought and Selective Laser Melted Ti64.

Selective laser melting (SLM) is a three-dimensional (3D) printing process that can manufacture functional parts with complex geometries as an alternative to using traditional processes, such as machining wrought metal. If precision and a high surface finish are required, particularly for creating miniature channels or geometries smaller than 1 mm, the fabricated parts can be further machined. Therefore, micro milling plays a significant role in the production of such miniscule geometries. This experimental study compares the micro machinability of Ti-6Al-4V (Ti64) parts produced via SLM compared with wrought Ti64. The aim is to investigate the effect of micro milling parameters on the resulting cutting forces (Fx, Fy, and Fz), surface roughness (Ra and Rz), and burr width. In the study, a wide range of feed rates was considered to determine the minimum chip thickness. Additionally, the effects of the depth of cut and spindle speed were observed by taking into account four different parameters. The manufacturing method for the Ti64 alloy does not affect the minimum chip thickness (MCT) and the MCT for both the SLM and wrought is 1 μm/tooth. SLM parts exhibit acicular α martensitic grains, which result in higher hardness and tensile strength. This phenomenon prolongs the transition zone of micro-milling for the formation of minimum chip thickness. Additionally, the average cutting force values for SLM and wrought Ti64 fluctuated between 0.072 N and 1.96 N, depending on the micro milling parameters used. Finally, it is worth noting that micro-milled SLM workpieces exhibit lower areal surface roughness than wrought ones.

Experimental Study on the Mechanical Behavior of Dry Corn Stalk Cutting.

This work presents an experimental study of cutting corn stalks for thermal energy generation. The study was carried out for the values of blade angle in the range of α = 30-80°, distance between the blade and the counter-blade g = 0.1, 0.2, 0.3 mm and the velocity of the blade V = 1, 4, 8 mm/s. The measured results were used to determine shear stresses and cutting energy. The ANOVA variance analysis tool was used to determine the interactions between the initial process variables and the responses. Furthermore, the blade load-state analysis was carried out, together with determining the knife blade strength characteristic, based on the determination criteria for the strength of the cutting tool. Therefore, the force ratio Fcc/Tx was determined as the determinant of strength, and its variance characteristic in the function of the blade angle, α, was used in the performed optimization. The optimization criteria entailed the determination of such values of the blade angle, α, for which the cutting force value, Fcc, and the coefficient of knife blade strength approached the minimum value. Hence, the optimized value of the blade angle, α, within the range 40-60° was determined, depending on the assumed weight parameters for the above-mentioned criteria.