Haci Saglam Faruk Unsacar Suleyman Yaldiz International Journal of Machine Tools amp Manufacture Investigation of the effect of rake angle and approaching angle on main cutting force and tool tip temperature ID: 379349
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Authors: Haci Saglam Faruk Unsacar Suleyman Yaldiz
International Journal of Machine Tools & Manufacture
Investigation of the effect of rake angle and approaching angle on main cutting force and tool tip temperature
Date of Publication: May 5, 2005
Presenter:
Matt Maxfield
Date: October 7, 2009Slide2
Function of this PaperCompare measured and calculated results of cutting force components and temperature variation on the tool tip of various tool geometries used in machining AISI 1040 SteelSlide3
The Importance of Cutting Force & TemperatureDue to more demanding manufacturing processes and systems, the requirements for reliable technological information have increasedCutting forces are mainly affected by cutting speed, feedrate, undeformed chip thickness, cutting tool material, tool geometry, depth of cut and tool wearThere are many empirical equations for cutting force but experimental measurements are more reliablePredicting temperature distribution is important in determining the maximum cutting speedSlide4
ReferencesSlide5
How does this relate to us?Learning about machining processesLearning about the effects of tool geometry Rake face - tool’s leading edgeRake angle - slant angle of tool’s leading edge (α)Flank - following edge of cutting toolRelief angle – angle of tool’s following edge above part surface Slide6
Design and ParametersTested practically under workshop conditionsEach test conducted with sharp uncoated carbide tool insertConstantsDepth of cutCutting speedVariablesApproach angleRake angle Work piece material selected to represent the major group used in industry (AISI 1040 Steel)
Full factorial designSlide7
Method of Testing Experiments were carried out on a CNC turning machineMain cutting force (Fc), feed force (Ff), and thrust force (Ft) were measured using a three component turning dynamometerA radiation sensor was used for temperature measurement on the tool tipSlide8
Method of Testing Test conducted under dry conditionsFull factorial design of experimentExperimental results compared with calculated resultsSlide9
Calculating Forces and TemperaturesMain cutting force (Fc)Ac = chip cross-sectional areaKs = specific cutting force
Average temperature risePu
= friction power spent on the tool facePu = FuVcFu = friction force
Fu = Fc sin αr +Ff cosα
r
M
c
= metal removal
rate
C
s
= specific coefficient of heat of
workpieceSlide10
Experimental ResultsThe effect of approaching angle on main cutting force and tool tip temperatureSlide11
Experimental ResultsThe effect of rake angle on main cutting force and tool tip temperatureSlide12
Experimental ResultsThe effect of feedrate on main cutting force and tool tip temperatureSlide13
Correlations of Experimental vs. CalculatedDeviation of calculated cutting force components form measured valuesAverage deviation of main cutting force calculations for 64 experiments was 0.37%Slide14
Design ChallengesThe average deviation of the temperature for 64 experiments was 42%Due to the flowing chips some of the heat was conducted to the workpiece and an acurate
tool tip measurement was not able to be madeFor a reliable measurement a thermocouple should be embedded into the cutting insertSlide15
ConclusionsIncreasing the rake angle over its optimum value has a negative effect on tool’s performance and accelerates tool wear which leads to an increase in cutting forceIt is difficult to create a fully comprehensive model of all cutting parameters for cutting forceFeedrate = cutting forceRake angle = cutting forceOptimum rake angle = 12°
Optimum machining at γ=0° and χ=75° Slide16
ConclusionsHow does this paper help in industry?Practical in gaining a better understanding of the effects of rake angle and approach angle on cutting force but did have some design flaws in analyzing temperatureIs there any technical advancement?It adds to the current knowledge about cutting force variables by testing parameters not studied as frequentlyWhat industries are most affected by this research?Machinist who work with steel
Most industries