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1

Effect of Cutting-Edge Geometry on the Machinability of 316L Austenitic Steel

Grabowski Marcin, Małek Marcin, Teimouri Reza, Skoczypiec Sebastian

Advances in Science and Technology. Research Journal

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2024

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Vol. 18, no 1

110--117

EN

The paper focuses on the problem of selecting the correct tool geometry in high-speed milling of 316L stainless steel. Carbide milling cutters with two configurations of helix angle (40/42 degrees for tool#1 and 35/38 degrees for tool#2) with different cutting edge radiuses rn (i.e. 4 µm, 6 µm, 8 µm, 10 µm and 12 µm) were prepared and their impact on cutting force and roughness were analyzed. The obtained results revealed that the small changes in cutting edge radius rn have a significant effect on both cutting forces and surface roughness. In this context, irrespective to the type of the tool, increasing the cutting edge radius results in further cutting force. However, increasing the cutting edge radius shows different behavior on roughness while using different tool helix angles. For the tool#1, it was found that the surface roughness increases by increasing the cutting edge radius from 6 μm to 12 μm; while in the samples machined by tool #2, increase in cutting edge radius results in reduction of roughness. It was also found that irrespective to the values of cutting edge radius, the cutting force while using tool #1 is slightly less than the tool#2. In addition, the induced milling surface roughness of the samples machined by tool#2 is significantly less than the tool#1 where the mean value of Ra was reduced from 2.55 µm to 0.35 µm

2

Influence of cutting parameters and tool edge geometries on the machinability of AlSi aisi 52100 steel in hard whirling

Song Shuquan, Zhang Yu, Cheng Jiangtao, Zhang Hao, Guan Xiangyu, Zuo Dunwen, Shen Xiaoqiang

Engineering Transactions

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2023

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Vol. 71, iss. 3

399--417

EN

The synergistic effect of prepared tool edge and cutting parameters in hard whirling is still unclear, limiting its application in producing large precision ball screws. This paper aims to reveal the effect mechanism of cutting parameters and edge geometries in the whirling process to improve the stability of ball screw quality. A novel cutting force measurement strategy is proposed, and a systematic study of cutting force, surface quality and tool wear is implemented. The results show that small feed (less than 0.15 mm) and high cutting speed (more than 180 m/min) can ensure machining efficiency and improve surface quality. The machining quality can be improved when the edge radius is 10 µm, and the chamfer size is 0.1 mm × 20◦ . The tool with a 30 µm edge radius has a low probability of early failure, but the later wear is severe and timely sharpening is recommended. This study could guide cutting parameters and edge geometry optimization to improve the stability of the quality in hard whirling.

3

Studying the Behavior of the C45 Material when Changing the Tool Geometry Using the Finite Element Method

Pop Alina Bianca, Sandu Andrei Victor, Sachelarie Adrian, Țîțu Aurel Mihail

Archives of Metallurgy and Materials

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2022

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Vol. 67, iss. 2

653--659

EN

Machining with tool that have cutting edge radius provides components with high fatigue strength, microhardness of a large surface layer and plastic deformation. Finite element simulations of the cutting process give a better knowledge of the chip generation phenomenon, heat generation in the machining area, stress and temperature field results. This study emphasizes the true importance of the mathematical model that underlies the shape of the tool in the pre-processing steps of finite element analysis. The argument is that its achievement and definition depend on the network difficulty. This research purpose is to perform simulations series of orthogonal machining with different radius and depth of cut. In this way, conclusions on the impact of these variations on the whole cutting process were drawn. The finite element application used is Deform 2D, the Lagrange incremental method and the Johnson-Cook material model. The temperature distribution, stress distribution, von Mises stress distribution, effects on specific tool pressure and wear, and fluctuations in the cutting resistance of the tool tip and C45 workpiece were analyzed.

4

Zaokrąglanie krawędzi skrawających ostrzy z węglików spiekanych

Cichosz P., Kuzinovski M., Tomov M., Urych A.

Mechanik

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2018

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R. 91, nr 7

458--462

PL

Przedstawiono genezę zaokrąglania krawędzi ostrzy skrawających wykonanych z węglików spiekanych. Zaprezentowano różne obrabiarki i ścierniwa służące do wygładzania krawędzi skrawających. Porównano metody pomiaru promienia zaokrąglenia krawędzi. Zwrócono uwagę na możliwości zwiększenia trwałości narzędzi dzięki zastosowaniu nowych technologii wykańczania powierzchni roboczych narzędzi.

EN

The paper describes the origins of edge rounding of machine-cutting blades made of sintered carbides. Various processing machines and abrasive materials used to smoothen the cutting edges are presented. Various methods of measurement of the edge radius are compared. Stressed are the possibilities of improvement of tool durability through the use of new finishing process technologies for tool working surfaces.

5

Wpływ promienia zaokrąglenia krawędzi skrawającej na chropowatość powierzchni przy skośnym skrawaniu

Latoś H., Leppert T.

Zeszyty Naukowe. Mechanika / Akademia Techniczno-Rolnicza w Bydgoszczy

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2002

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Z. 52(240)

45-54

PL

W pracy przedstawiono badania wpływu promienia zaokrąglenia krawędzi skrawającej na chropowatość powierzchni obrobionej po toczeniu jednokrawędziowym nożem skośnym o prostoliniowej krawędzi skrawającej. Pokazano technikę kształtowania i pomiaru promienia zaokrąglenia krawędzi skrawającej.

EN

The study presents the effect of the cutting edge radius on the surface roughness as well as shaping and measuring the cutting edge methodology and techniques.

6

The influence of cutting edge radius on the cutting zone state.

Zębala W.

Advances in Manufacturing Science and Technology

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2002

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Vol. 26, nr 3

63-75

EN

The paper describes the results of cutting process modelling of medium carbon steel (0,33%C) machining by cemented carbides tools P20 with a specially prepared geometry: cutting adge radius rn = 0,01; 0,03; 0,05 mm, rake angle gamma n = 6 degrees, clearance angle alfa n = 6 degrees, tool cutting adge angle kappa r = 45 degrees, corner radius re = 0,03 mm, flat rake face. The modelling research purpose was to determine the influence of cutting edge radius on the cutting zone state (temperature and stress distribution in the tool and chip). The modelling process was realized in two stages: the initial calculations, permitting the geometry of the model and boundary condition determination and the main numerical calculations, based on the boundary element method, permitting the determination of the temperature and stress fields distributions in the cutting zone. The geometry of the model was defined from the shear angle calculation. Results of the test were presented in the form of distribution maps of temperature, Von Mises effective stress and maximum shear stress inside the whole zutting zone.

PL

W pracy przedstawiono modelowanie procesu skrawania stali średniowęglowej (),33%C) narzędziami z węglików spiekanych grupy P20 o odpowiednio przygotowanej geometrii ostrzy: promień zaokrąglenia krawędzi skrawającej rn = 0,01; 0,03; 0,05 mm, kąt natarcia gamma n = 6 stopni, kąt przyłożenia alfa n = 6 stopni, kąt przystawienia kappa r = 45 stopni, promień naroża re = 0,03 mm, płaska powierzchnia natarcia. Celem badań modelowych było określenie wpływu promienia zaokrąglenia krawędzi skrawającej na stan strefy skrawania (rozkład temperatury i naprężeń w ostrzu i wiórze). Proces modelowania zrealizowano w dwóch etapach: obliczenia początkowe, pozwalające na ustalenie geometrii modelu i warunków brzegowych, oraz główne obliczenia numeryczne oparte na metodzie elementów brzegowych, pozwalające na określenie pól rozkładu temperatury i naprężeń w strefie skrawania. Geometria modelu została ustalona przez obliczenia kąta ścinania. Wyniki badań zapreznetowano w postaci map rozkładu temperatury, naprężeń zredukowanych według hipotezy Misesa oraz naprężeń stycznych wewnątrz całej strefy skrawania.