Side Cutting Edge Angle Research Articles

Optimization of tool wear and surface roughness in ST-37 steel turning process with varying tool angles and machining parameters

The process of cutting low carbon steel (ST-37) typically utilizes High-Speed Steel (HSS) tools owing to their high hardness, affordability, and ease of shaping tool geometry. In machining, tool geometry plays a crucial role in the material cutting process and determines the quality of the final product, particularly surface roughness. The objective of this research is to achieve optimal surface roughness by varying the tool geometry and nose radius. This study employed an experimental approach using ST-37 and HSS tools. The variations in tool geometry include side rake angles of 12°, 15°, and 18°; side cutting edge angles of 85°, 80°, and 75°; and nose radii of 0 mm, 0.4 mm, and 0.8 mm. The machining parameters applied consist of a cutting depth of 1 mm and 2 mm, spindle rotation speeds of 185 rpm, 425 rpm, and 624 rpm, and a feed rate of 0.05 mm/rev, 0.075 mm/rev, and 0.1 mm/rev. Tool wear measurements were captured using a USB camera, whereas the surface roughness was assessed using a surface roughness tester. The impact of the tool geometry on the surface roughness was analyzed using the Taguchi-Grey Relational Analysis (Taguchi-GRA) and ANOVA methods. The optimal combination for ST-37 lathe machining with a sharpening tool is: A1 (cutting depth 1 mm), B1 (cutting speed 17.42 m/min), C3 (feed 0.05 mm/rev), D1 (corner radius 0 mm), E3 (side rake angle γ 18°), and F3 (side cutting edge angle γ 75°). According to the Analysis of Variance (ANOVA), three factors—cutting speed, tool tip angle, and chip angle—should be considered to achieve minimal tool wear and desirable surface roughness during machining

Cutting fluid role in the machinability of AZ91/SiC composite: Tool wear and surface roughness

Metal matrix composites (MMC) introduced special features such as resistance to wear and high strength to weight ratio and these characteristics categorized them as difficult-to-cut materials in the field of machining. In the current paper, a novel study on the cutting fluid emulsion 5% role in the machinability of a magnesium-based metal matrix composite reinforced by silicon carbide (SiC) particles is presented. AZ91 magnesium alloy, with nominal composition Mg-9Al-1Zn, composites were made using stir casting method. Then, the composite samples were machined and the cutting parameters such as cutting speed, feed rate and side cutting edge angle were varied to assess their effects on the wear and surface roughness. To measure and analyze the wear, optical and scanning electron microscope (SEM) were used. Also, elemental analysis through energy-dispersive X-ray spectroscopy (EDS) was accomplished. Surface roughness of machined samples were measured by a profilometer and 3D surface topography. Results of SEM and EDS images indicated that SiC particles included in the composites act as grinders and remove the surface of tool even in a short time because of the severe abrasion. Additionally, surface of machined MMCs contains some defects such as cracks, broken SiC, and unwanted deformations. Using cutting fluid emulsion 5% enhanced the tool life as well as the surface quality remarkably for different cutting speeds, feed rates and cutting edge angles although finished surface of the samples were oxidized. Also, the cutting fluid considerably reduced the amount of adhered materials on the flank face.

INFLUENCIA DEL ÁNGULO DE POSICIÓN EN EL DISEÑO DEL ROMPEVIRUTAS: ESTUDIO DE HERRAMIENTAS DE TORNEADO DINÁMICO Y DE ALTO AVANCE EN INCONEL® 718

Dynamic turning is a recent technology that allows inserts with different cutting edges to be used and the side cutting edge angle to be modified by controlled spindle rotation and synchronised variation of the cutting parameters. This makes it possible to eliminate downtime by reducing tool changes. Chip breaking is a relevant fact in the turning of aeronautical parts, as it allows a higher heat dissipation performance when working with heat-resistant superalloys, materials that degrade inserts rapidly. An initial study has been carried out, using different fixed side cutting edge angles, to test the chipbreaker performance of an experimental dynamic turning insert in order to adapt its design to the machining of aeronautical components, obtaining that, although the cutting performance is good, the chipbreaker does not perform correctly in finishing conditions, and therefore it must be redesigned by reducing its distance to the cutting edge. Keywords: dynamic turning; high feed; aerospace superalloy; chipbreaker, side cutting edge angle.

Prediction of cutting forces including tool wear in high-feed turning of Nimonic® C-263 superalloy: A geometric distortion-based model

The hottest parts of aerospace components are often made of heat-resistant materials. Due to the high requirements in such parts and accelerated wear rates, machining is a challenging task. Recently, new high-feed machining strategies were launched by tool developers. The main idea is ​​using extremely low side cutting edge angles Kr so that high feeds and low chip thicknesses are both possible. These tools are supposed to be decisive for greater productivity rates. However, tool wear’s traceability is the key in order to replace them before dramatic failure. Additionally, the machining of such aggressive materials must be assisted by high pressure cooling. To reduce the environmental footprint, cryogenic techniques look promising. This work proposes a prediction cutting model for high feed turning of Nimonic© C-263 superalloy including tool wear. It allows to consider the geometric tool deterioration, which is the key mechanism in the evolution of cutting forces on this superalloy. The concept of reducing side cutting edge angle and its benefit on productivity is also explored. Besides, oil emulsion and CO2 cryogenic conditions are also compared. The wear prediction model showed good agreement with the experimental results by obtaining relative errors of less than 5 % using cutting speeds lower than 100 m/min and less than 14 % for higher speeds. The benefit of reducing the side cutting edge angle on tool life 8 (from 90° to 30°) was also demonstrated by increasing tool life x3 (from 8 to 24 min). Notches were removed. In contrast, using cryogenic conditions do not seem to be a clear advantage over this type of superalloy. Finally, optimum conditions were found: using vc = 70 m/min, f = 0.2 mm/rev and = 1 mm, good surface finish, chip control and tool life can be satisfied.

Determining the force formulas while orthogonal shaped turning by tools with convex radial cutting edge

Orthogonal shaped turning is a non-free cutting process, because the main geometric and force parameters are variable while radial infeed of a tool: side cutting edge angle (SCEA), width and thickness of cut, rake angle and flank angle etc.. In this regard, the existing force dependencies, which are used for stationary conditions of cutting, are not applicable. Analytical dependences for calculating variable cutting forces while orthogonal turning are obtained on the basis of experimental studies in this work. This approach takes into account the cutting areas and corresponding specific pressures using correction coefficients for changing cutting conditions during machining. The obtained calculated dependences are universal and can be used for a free cutting process, i.e. while cutting with a constant value of radial infeed. The obtained analytical dependences make it possible to calculate the energy parameters in the cutting process: power, torque and work in conditions of orthogonal shaped turning.

Analysis of Cutting Parameters in CNC Turning of AISI 52100 Steel with Coated Cutting Tool

In the automotive industry, machining is an essential part of the production process. On mild steel, a turning process was utilised to create shafts of varied diameters. This work attempts to optimise multiple factors such as surface roughness, MRR, and tool wear during turning operations on various steel grades. The average surface roughness (Ra) is one of the most important measurements of surface quality during the machining process, and it is primarily influenced by a number of machining parameters such as true rake angle and side cutting edge angle, cutting speed, feed rate, depth of cut, nose radius, and machining time. The Taguchi technique was used to build a surface roughness model to study how machining factors such as feed rate, tool geometry, nose radius, and machining duration impact the roughness of the surface created during the dry turning phase. This study demonstrates how to determine surface roughness values for CNC turning of AISI 52100 steel with varying coated tool nose radius using tribiological parameters. The test was carried out on a commercial CNC machine with coated tool nose radiuses of 0.4, 0.8, and 1.2 mm. Further investigation revealed that the CNC machine's design had been completed in Solid Works. Static and modal analyses were carried out using ANSYS Workbench. A static structural analysis of a CNC machine was carried out using 1G lading, which met the minimum Yield Strength requirement.

Effect of geometrical parameters and tool pattern of multi-tooth sawing on cutting of sheet molding compound composite: FE study

Short glass fiber composites, particularly sheet molding compound (SMC) materials, are becoming increasingly important alternative in various contemporary aerospace, automotive, and electronic applications. For these manufacturing industries, the quality of the machined SMC composite is still a challenging target. The article proposes a new tool design with an offset between teeth to minimize friction, limit damage and promote chip removal when drilling composite materials. The effects of the tool’s geometric parameters, especially the rake, the inclination and the complementary side cutting edge angles on the material removal process, as well as the cutting and thrust forces, are investigated. A 3D finite element model of a representative multi-tooth tool is developed using the ABAQUS\\Explicit code. The results show that fine-tuning the geometric parameters of the tool reduces the induced machining damage and enhances the chip removal and the flow evolution. The rake angle has a significant influence on the cutting and thrust forces. However, both forces are insensitive to the inclination angle. The complementary side cutting edge angle influences only the thrust force. The presented outcomes not only give insights into the cutting process, but also improve the SMC machinability.

Accurate Modeling of Working Normal Rake Angles and Working Inclination Angles of Active Cutting Edges and Application in Cutting Force Prediction.

The normal rake angle is an important geometric parameter of a turning tool, and it directly affects the accuracy of the cutting force prediction. In this study, an accurate model of the working normal rake angle (WNRA) and working inclination angle (WIA) is presented, including variation in the cutting velocity direction. The active cutting edge of the turning tool is discretized into differential elements. Based on the geometric size of the workpiece and the position of the differential elements, the cutting velocity direction of each differential element is calculated, and analytical expressions for the WNRA, WIA, and working side cutting edge angle are obtained for each differential element. The size of the workpiece is found to exert an effect on the WNRA and WIA of the turning tool. The WNRA and WIA are used to predict the cutting force. A good agreement between the predicted and experimental results from a series of turning experiments on GH4169 with different cutting parameters (cutting depth and feed rate) demonstrates that the proposed model is accurate and effective. This research provides theoretical guidelines for high-performance machining.

3D FE modeling and experimental analysis of residual stresses and machining characteristics induced by dry, MQL, and wet turning of AA6061-T6

The present research study aimed to investigate the influences of turning environments and parameters on machining temperature (MT), machining forces (MFs), and axial surface residual stresses (ASRS) in turning operation of AA6061-T6. Turning environments included DRY, minimum quantity lubrication (MQL), and WET modes, and turning parameters consisted of cutting speed (), feed rate (), depth of cut (), tool nose radius (), side cutting edge angle (SCEA), and back rake angle (BRA). A 3D finite element (FE) model was developed to predict MT, MFs, and ASRS for different turning environments and parameters and was validated by experimental measurements. The results showed that increasing feed rate led to a higher tensile ASRS while using tools with a nose radius of 0.4 resulted in lower ASRS. In addition, the deviation of SCEA from 0° to positive or negative values caused higher tensile ASRS. ASRS increased with decreasing BRA from 0° to –15°. The variation of ASRS was found to be more sensitive to thermal effects than to mechanical ones. The results further confirmed that in a turning process, the competition between the machining forces and temperature was the fundamental factor that determined the extent of residual stresses.

Combination of high feed turning with cryogenic cooling on Haynes 263 and Inconel 718 superalloys

Abstract The machining of heat resistant superalloys (HRSA) is one of the most challenging tasks for machinists. Unfortunately, the turning of these difficult-to-cut materials is very common in the manufacturing of cases for gas turbines components due to their excellent mechanical properties. Traditionally, these operations are very time consuming. In order to avoid failure and part rejection, very conservative cutting parameters are selected; so, there is a great margin to optimize cutting conditions in aerospace applications. Besides, the minimization or avoidance of coolant is day-to-day a shared practice. All these factors make the turning of HRSA a very complex problem. Lately, high-feed turning technique has emerged as an alternative to traditional turning for a faster, more productive, manufacturing. It is based on moving the tool from the jaws towards the tailstock in reverse mode with a very low side cutting edge angle. It is a promising process but rather unknown. This paper presents an experimental investigation of the cutting forces and their prediction in high feed turning of Nickel-Chrome based superalloys. Besides, the effects of using oil emulsion and CO2 cryogenic coolant were also studied. Straight turning tests on different aerospace materials, Inconel 718 and Haynes 263, were compared against AISI 1055, using comparable cutting conditions. After the tests, surface roughness was also examined with both types coolants. The results indicated a good agreement between model predictions and experimental results for the three tested materials. It was also shown that while oil emulsion was the best option for Inconel 718, cryogenic cooling with CO2 can open the path towards a more efficient and cleaner turning in the case of Haynes 263.

Statistical modeling, Sobol sensitivity analysis and optimization of single-tip tool geometrical parameters in the cortical bone machining process.

Machining and cutting of cortical bones are very common and important in the field of orthopedic surgeries. Considerable advances in bone machining are obtained by using computer numerical control machines and automatic surgery robots but still, researches are needed to investigate the effects of machining parameters in bone machining. In this article, for the first time, the effect of geometrical parameters of the single-tip tool on cortical bone machining is studied. The machining parameters included in the investigation are rake angle, back rake angle and side cutting edge angle and the response surface methodology is used to analyze the obtained surface quality according to a second-order regression model. The sensitivity of surface quality to the input parameters was measured by applying Sobol sensitivity analysis and the results are optimized by the Derringer algorithm. Finally, the optimum tool is determined as 15° rake angle, -5° back rake angle and 30° side cutting edge angle. Furthermore, the sensitivity of the surface quality to the input parameters is determined as 52% for rake angle, 31% for side cutting edge angle and 17% for back rake angle.

Parametric optimization and process capability analysis for machining of nickel-based superalloy

The manufacturing of parts from nickel-based superalloy, such as Inconel-800 alloy, represents a challenging task for industrial sites. Their performances can be enhanced by using a smart cutting fluid approach considered a sustainable alternative. Further, to innovate the cooling strategy, the researchers proposed an improved strategy based on the minimum quantity lubrication (MQL). It has an advantage over flood cooling because it allows better control of its parameters (i.e., compressed air, cutting fluid). In this study, the machinability of superalloy Inconel-800 has been investigated by performing different turning tests under MQL conditions, where no previous data are available. To reduce the numerous numbers of tests, a target objective was applied. This was used in combination with the response surface methodology (RSM) while assuming the cutting force input (Fc), potential of tool wear (VBmax), surface roughness (Ra), and the length of tool–chip contact (L) as responses. Thereafter, the analysis of variance (ANOVA) strategy was embedded to detect the significance of the proposed model and to understand the influence of each process parameter. To optimize other input parameters (i.e., cutting speed of machining, feed rate, and the side cutting edge angle (cutting tool angle)), two advanced optimization algorithms were introduced (i.e., particle swarm optimization (PSO) along with the teaching learning-based optimization (TLBO) approach). Both algorithms proved to be highly effective for predicting the machining responses, with the PSO being concluded as the best amongst the two. Also, a comparison amongst the cooling methods was made, and MQL was found to be a better cooling technique when compared to the dry and the flood cooling.

Sustainable machining of aerospace material – Ti (grade-2) alloy: Modeling and optimization

The application of sustainable techniques in the machining of aerospace materials is quite prominent for attaining viability with respect to economic and environmental aspects. The recently embraced method in the context of sustainable machining includes the application of MQL (Minimum Quantity Lubrication) technique. This article presents an experimental investigation, comparison of empirical and experimental results, complemented with a desirability optimization technique, for study the impact on cutting forces, surface roughness, tool wear, surface topography, micro-hardness and surface chemical composition in the turning of the aerospace material – titanium (grade-2) alloy considering MQL conditions. In order to achieve this aim, firstly, the turning experiments were performed under varying conditions of process parameters such as cutting speed, feed rate and approach angle by using response surface methodology (RSM). Then, the analysis of variance and regression analysis were considered to analyze the effect of machining parameters on selected responses. Further, the comparison of empirical and experimental results for cutting force components has been made by using Kienzle approach. In the end, the model validation is performed by comparing the analytical predicted results of cutting forces with experimental and desirability approach that are in good agreement. The investigations showed that turning at low cutting speeds (200 m/min), low feed rates (0.10 mm/rev) and high side cutting edge angle (90°) ensures the high quality of surface roughness, lower cutting forces, tool wear and micro-hardness.

Investigation of Effects of Tool Geometry Parameters on Cutting Forces, Temperature and Tool Wear in Turning Using Finite Element Method and Taguchi’s Technique

Turning is one of the most widely metal cutting methods. Machines, tool geometry and machining parameters are the main factors influencing machining quality and efficiency. So there is a lot of research on it. This paper studies on the influence of the geometrical parameters of the tool including: back rake angle (BR), side rake angle (SR) and side cutting-edge angle (SCEA) on cutting forces, temperature and tool wear in turning using FEM (by Deform 3D finite element simulation software) and Taguchi’s technique (by Minitab16 statistical software) is used to design the experiment and to analyze output quality characteristics from simulation results. And the optimum tool geometry parameters are given.

Machining Parameters Optimization of Titanium Alloy using Response Surface Methodology and Particle Swarm Optimization under Minimum-Quantity Lubrication Environment

The present paper depicts an application of response surface methodology (RSM) and particle swarm optimization (PSO) technique for optimizing the machining factors in turning of titanium (Grade-II) alloy using cubic boron nitride insert tool under minimum quantity lubricant (MQL) environment. The three machining factors, i.e., cutting speed (Vc), feed rate (f) and side cutting edge angle (approach angle π), are designed as three factors by using RSM design, which is withal subject to several constraints including tangential force (Fc), tool wear (VBmax), surface roughness (Ra) and tool-chip contact length (L). The multiple regression technique was used to establish the interaction between input parameters and given responses. Moreover, the results have been presented and optimized process parameters are acquired through multi-response optimization via desirability function as well as the PSO technique. The lower values of Vc (200 m/min), f (0.10 mm/rev) and higher values of ϕ (90°) are the optimum machining factors for minimizing the aforementioned responses. It was also observed that the selected responses predicated on PSO are much closer as that of the values acquired in view of the desirability function approach. Henceforth, PSO has the potential to cull appropriate machining factors while turning titanium (Grade-II) alloys under MQL conditions.

Effect of Machining Parameters and Machining Time on Surface Roughness in Dry Turning Process

The most important measures of surface quality during the machining process is the average surface roughness (Ra), and it is mostly caused by many machining parameters, such as true rake angle and side cutting edge angle, cutting speed, feed rate, depth of cut, nose radius, machining time etc. This paper a model of surface roughness was developed based on the response surface method to investigates the machining parameters such as feed rate, tool geometry, nose radius, and machining time, affecting the roughness of surface produced in dry turning process. The experiment has been designed and carried out on the basis of a three level factorial design. Obtained results are in good accordance with the published results in the field, validating the effectiveness of regression analysis in modeling of surface roughness in dry turning process.

Simple Estimation Method of Cutting Forces in Cylindrical Turning

For the purpose of developing a new simple estimation method of metal cutting forces, firstly, orthogonal cutting data are examined from the point of view that material constants other than shear stress on the shear plane, which is characteristic of the material used and is not affected by cutting conditions, may exist. As a result, the authors find that the principal cutting force is approximately proportional to the chip thickness in a relatively wide range of cutting conditions. Thus, the principal cutting force is proportional to the unit chip sectional area, and the proportional constant is named “ chip constant ” for convenience in this paper. Then, the concept of the chip constant is introduced into the cutting mechanism of cylindrical turning, and three cutting force components are analyzed. The estimated values of the three components are compared with measured ones in regard to the change of side cutting edge angle. Since only two constants of the material used, i.e., the chip constant and shear stress assumed from the chip hardness, and measurement of the chip thickness are required, this estimation method of cutting forces is simple and handy.

Analysis of tool wear patterns in finishing turning of Inconel 718

This paper focuses on the analysis of tool wear mechanisms in finishing turning of Inconel 718, one of the most used Ni alloys, both in wet and dry cutting. Cemented carbides, ceramics and CBN tools are suitable for machining Ni alloys; coated carbide tools are competitive for machining operations of Ni alloys and widely used in industry. Commercial coated carbide tools (multilayer coating TiAl/TiAlN recommended for machining Ni alloys) were studied in this work. The feasibility of two inserts tested for dry cutting of Inconel 718 has been shown in the work. Experimental test were performed in order to analyze wear patterns evolution. It was found great influence of side cutting edge angle in tool wear mode.

Comparison of central composite and orthogonal array designs for cutting force and surface roughness prediction modelling in turning

Development of empirical models in turning operation has been a major activity in metal cutting research. This paper presents an application of central composite face centred (CCF) and L18(21 × 37) orthogonal array designs for developing cutting force and surface roughness models in case of turning AISI 1015 steel with HSS tool. Three process parameters namely cutting speed, feed, depth of cut and three tool parameters namely side cutting edge angle, inclination angle, normal rake angle were considered in developing the cutting force and surface roughness models. Each parameter was set at three levels. Based on the experimental data, mathematical models in terms of process and tool parameters were developed using multiple linear regression. Finally, central composite and orthogonal array designs are compared with respect to effect analysis and empirical model building. Confirmation tests were performed to verify the predictability of the developed models.

A methodology to estimate the forces on the tool insert in finish hard turning

The work presents a methodology to predict the forces on a worn cutting tool insert in finish hard turning when cutting action is limited to the round nose of the insert. The forces acting on the sharp tool, due to material shear at the cutting edge, were estimated using minimum energy criterion. The induced forces due to chip tool rubbing were estimated using the rake face normal and shear stresses. Instantaneous flank wear was used to estimate the increase in tool forces due to rubbing at the flank-work interface. The flank wear is assumed to be homogeneous all over the tool nose involved in cutting. Machining parameters and the data related to the tool and work piece material used in the model were taken from a previous work that used an equivalent side cutting edge angle to model the worn tool forces. Force estimation from the proposed model was found to be in coherence with the predictions and measured forces from the referred work.