Journal articles: 'Machining chip'

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Anicic, Obrad, Srdjan Jovic, Srdan Tasic, Aleksa Vulovic, and Milivoje Jovanovic. "Temperature detection in cutting zone for different forms of chip shapes during machining process." Sensor Review 38, no. 1 (January 15, 2018): 102–5. http://dx.doi.org/10.1108/sr-07-2017-0141.

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Purpose This study aims to detect the temperature distribution in the cutting zone during the machining process. Furthermore, temperature influence in the cutting zone on the forms of chip shapes during the turning of Steel 30CrNiMo8 was evaluated. It is very important to use optimal machining parameters to get the best production results or for high control of the machining process. Design/methodology/approach Temperature distribution in the cutting zone during the machining process could affect the forms of chip shapes. Forms of chip shapes could be considered as the most important indicator for the quality of the machining process. Findings Therefore, in this study, the forms of chip shapes based on the temperature distribution in the cutting zone were examined. Originality/value It was found that the snarled chip type and the loose chip type have the highest temperature variation during the machining process.

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Fang, Ning. "A Quantitative Sensitivity Analysis of Cutting Performances in Orthogonal Machining with Restricted Contact and Flat-Faced Tools." Journal of Manufacturing Science and Engineering 126, no. 2 (May 1, 2004): 408–11. http://dx.doi.org/10.1115/1.1643081.

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This paper presents a new quantitative sensitivity analysis of cutting performances in orthogonal machining with restricted contact and flat-faced tools, based on a recently developed slip-line model. Cutting performances are comprehensively measured by five machining parameters, i.e., the cutting forces, the chip back-flow angle, the chip up-curl radius, the chip thickness, and the tool-chip contact length. It is demonstrated that the percentage of contribution of tool-chip friction to the variation of cutting performances depends on different types of machining operations. No general conclusion about the effect of tool-chip friction should be made before specifying a particular type of machining operation and cutting conditions.

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Kouril, M. "Chip machining of cemented carbides." Metal Powder Report 53, no. 7-8 (July 1998): 44. http://dx.doi.org/10.1016/s0026-0657(98)85115-1.

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Manyindo, B. M., and P. L. B. Oxley. "Modelling the Catastrophic Shear Type of Chip When Machining Stainless Steel." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 200, no. 5 (September 1986): 349–58. http://dx.doi.org/10.1243/pime_proc_1986_200_138_02.

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When machining materials such as stainless steel and titanium the removed chip is characterized by a serrated (saw-tooth) outer surface and large cyclic variations in macrostrain within the chip. The present paper presents a model for the process producing such chips. The model is shown to represent accurately experimental results derived from cine films and photomicrographs of the chip formation process obtained when maching stainless steel.

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Ruan, Jing Kui, Ying Lin Ke, and Yong Yang. "The Finite Element Analysis of Serrated Chip Formation in High-Speed Cutting Auto Panel Dies." Materials Science Forum 575-578 (April 2008): 293–98. http://dx.doi.org/10.4028/www.scientific.net/msf.575-578.293.

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On the base of analyzing material constitutive model, chip-tool contact friction, and chip separation and fracture, a finite element model (FEM) was built to study the high-speed machining process of alloy cast-iron. The shaping process of serrated chip in high-speed milling alloy cast-iron was simulated and analyzed in detail. It was shown that machining parameters affect the serrated chip forming greatly. The model can be used to optimize machining parameters, prolong tool life and improve machining surface quality.

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Anicic, Obrad, Srdjan Jovic, Ivica Camagic, Mladen Radojkovic, and Nenad Stanojevic. "Measuring of cutting forces and chip shapes based on different machining parameters." Sensor Review 38, no. 3 (June 18, 2018): 387–90. http://dx.doi.org/10.1108/sr-08-2017-0169.

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Purpose The main aim of the study was to measure the cutting forces and chip shapes based on different machining parameters. Design/methodology/approach To get the best optimal machining conditions, it is essential to use the best combination of machining parameters. Although some machining parameters are not important for the process, there are machining parameters which are very important for the machining process. Findings It is essential to determine which machining parameters are the most dominant to make the optimal machining conditions. Originality/value Six different chip shapes are obtained according to ISO standardization. It was determined that the different cutting forces occurred for the different chip shapes.

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Mann, James B., Yang Guo, Christopher Saldana, Ho Yeung, W. Dale Compton, and Srinivasan Chandrasekar. "Modulation-Assisted Machining: A New Paradigm in Material Removal Processes." Advanced Materials Research 223 (April 2011): 514–22. http://dx.doi.org/10.4028/www.scientific.net/amr.223.514.

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Modulation Assisted Machining (MAM), based on controlled superimposition of low-frequency modulation to conventional machining, effects discrete chip formation and disrupts the severe contact condition at the tool-chip interface. The underlying theory of discrete chip formation and its implications are briefly described and illustrated. Benefits such as improved chip management and lubrication, reduction of tool wear, enhanced material removal, particulate manufacturing and surface texturing are highlighted using case studies. MAM represents a new paradigm for machining in that it deliberately employs ‘good vibrations’ to enhance machining performance and capability.

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Jovic, Srdjan, Dragan Lazarevic, and Aleksa Vulovic. "Analyzing of the sensitivity of chip formation during machining process." Sensor Review 37, no. 4 (September 18, 2017): 448–50. http://dx.doi.org/10.1108/sr-06-2017-0120.

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Purpose The paper aims to analyze chip formation during machining process since it can be a very important indicator for the quality of the machining process, as some chip forms can be undesirable. Design/methodology/approach It is essential to determine the sensitivity of the chip formation on the basis of different machining parameters. The main goal of the study was to analyze the sensitivity of the chip formation during the machining process by using adaptive neuro-fuzzy inference system (ANFIS). Findings According to the results, the chip formation is the most sensitive to feed rate. Originality/value Different cutting tests were performed to monitor the chip formation on the basis of the cutting forces and the cutting displacement. ANFIS was used to estimate the sensitivity of the chip formation during the cutting process on the basis of different parameters.

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Rahman, M. Azizur, Md Shahnewaz Bhuiyan, Sourav Sharma, Mohammad Saeed Kamal, M. M. Musabbir Imtiaz, Abdullah Alfaify, Trung-Thanh Nguyen, et al. "Influence of Feed Rate Response (FRR) on Chip Formation in Micro and Macro Machining of Al Alloy." Metals 11, no. 1 (January 16, 2021): 159. http://dx.doi.org/10.3390/met11010159.

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In this paper, the investigation of chip formation of aluminum alloy in different machining strategies (i.e., micro and macro cutting) is performed to develop a holistic view of the chip formation phenomenon. The study of chip morphology is useful to understand the mechanics of surface generation in machining. Experiments were carried out to evaluate the feed rate response (FRR) in both ultra-precision micro and conventional macro machining processes. A comprehensive study was carried out to explore the material removal mechanics with both experimental findings and theoretical insights. The results of the variation of chip morphology showed the dependence on feed rate in orthogonal turning. The transformation of discontinuous to continuous chip production—a remarkable phenomenon in micro machining—has been identified for the conventional macro machining of Al alloy. This is validated by the surface crevice formation in the transition region. Variation of the surface morphology confirms the phenomenology (transformation mechanics) of chip formation.

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Tang, Zhi An, Chang Yi Liu, and Jun Jie Yi. "Finite Element Simulation of Ultrasonic Vibration Orthogonal Cutting of Ti6Al4V." Advanced Materials Research 97-101 (March 2010): 1933–36. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.1933.

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In this paper Finite Element Methods (FEM) were used to simulate the ultrasonic vibration Orthogonal cutting of titanium alloy Ti6Al4V. Machining conditions were similar to those used for manufacture. Material constitutive applied Johnson-Cook model combining elastic and plastic deformation, the material hardening for extreme shear strain and strain rate, material softening for adiabatic shear of chip flow-zone. Chip separated criteria adopted arbitrary Lagrangian Euler algorithm (ALE). Heat sources included the rake face chip flow under conditions of seizure and chip/tool friction, clearance face tool/workpiece friction. Thus, the orthogonal ultrasonic vibration machining of Ti6Al4V FEM models were established. The simulation results included the chip formation, the cutting force/stress and temperature distributions through the primary shear zone and the chip/tool contact region. The cutting force, cutting temperature of the ultrasonically and conventionally machining were compared. The reasons of the decrease of chip deformation coefficients, cutting force and temperature and the increase of shear angle in ultrasonic machining were discussed.

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Bi, Xue Feng, G. Sutter, Gautier List, and Yong Xian Liu. "Influence of Chip Curl on Tool-Chip Contact Length in High Speed Machining." Materials Science Forum 626-627 (August 2009): 71–74. http://dx.doi.org/10.4028/www.scientific.net/msf.626-627.71.

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The tool-chip contact length, as an important parameter controlling the geometry of tool crater wear and understanding chip formation mechanism, is widely investigated in machining. The aim of this paper is to study the influence of chip curl on tool-chip contact length by means of experimental observations with high cutting speed. The relationship between tool-chip contact length, chip radius of curvature and uncut chip thickness was investigated. Experimental results show the effect of increasing spiral chip radius on tool-chip contact length with low uncut chip thickness in high speed machining.

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Thakur, A., and S. Gangopadhyay. "Evaluation of micro-features of chips of Inconel 825 during dry turning with uncoated and chemical vapour deposition multilayer coated tools." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, no. 6 (August 5, 2016): 979–94. http://dx.doi.org/10.1177/0954405416661584.

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Mechanism of chip formation during dry machining of Ni-based super alloys needs considerable research attention as it directly or indirectly affects different aspects of machinability. Therefore, the present research work aims at understanding the mechanism of chip formation with the help of various chip characteristics during dry machining of Inconel 825, a nickel-based super alloy. The influence of multilayer coating deposited using chemical vapour deposition, cutting speed and machining duration has been investigated on types and form of chips, along with different characteristics of chip like shear band thickness, saw-tooth distance, equivalent chip thickness, saw-tooth angle and chip segmentation frequency. Chip–tool contact length, hardness and crystallographic orientation (through X-ray diffraction) of chip have also been studied. Furthermore, different machining characteristics such as cutting force, apparent coefficient of friction and cutting temperature have also been determined for explaining the mechanism of various aspects of chip formation. The results indicated that coated tool restricted sharp increase in shear band thickness with cutting speed and resulted in reduction in saw-tooth distance, saw-tooth angle, equivalent chip thickness, chip hardness and deformation on grains while exhibiting increase in chip segmentation frequency in comparison with its uncoated counterpart.

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Wu, C. L., and Z. R. Wang. "Effect of Machining Parameters on Deformation Field in Machining by Finite Element Method." Applied Mechanics and Materials 80-81 (July 2011): 942–45. http://dx.doi.org/10.4028/www.scientific.net/amm.80-81.942.

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Formation of chip is a typical severe plastic deformation progress in machining which is only single deformation stage. The large strain, low temperature and deformation force are the major premises to create significant microstructure refinement in metals and alloys. A finite element method was developed to characterize the distribution of strain, temperature and cutting force. Effects of rake angle, cutting velocity and friction on effective strain, cutting force imposed in the chip are researched and the conditions which lead to the large stain deformation in machining are highlighted. The results of simulation have shown that chip materials with ultrafine grained and high hardness can be produced with negative tool rake angle at some lower cutting velocity.

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Yao, Xifan. "Fuzzy-Chip-Based Control and Its Application to Adaptive Machining." Journal of Dynamic Systems, Measurement, and Control 125, no. 1 (March 1, 2003): 74–79. http://dx.doi.org/10.1115/1.1543156.

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The use of fuzzy chip to implement the control of machining processes is investigated. The hardware solution can process rules in fuzzy controllers at high speed. In this paper, fuzzy-chip-based regular and self-tuning controllers are developed to maintain a constant cutting force during machining processes under time-varying cutting conditions. In the fuzzy-chip-based self-tuning controller, two knowledge bases are employed. One base is used to implement the inference of control rules and the other to execute tuning rules for adjusting the output scaling factor on line. The structure makes the proposed fuzzy-chip-based self-tuning controller different from those fuzzy adaptive controllers developed in machining. Those fuzzy-chip-based controllers are characterized by the simple structure and practical applicability for real-time implementation. Both simulation and experimental results on machining processes show that the fuzzy-chip-based controllers demonstrate feasibility, applicability, and adaptability.

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Du, Hongying, Andrey Karasev, Thomas Björk, Simon Lövquist, and Pär G. Jönsson. "Assessment of Chip Breakability during Turning of Stainless Steels Based on Weight Distributions of Chips." Metals 10, no. 5 (May 21, 2020): 675. http://dx.doi.org/10.3390/met10050675.

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Currently, the available evaluation methods for determining the chip breakability in the industry are mainly based on subjective visual assessment of the chip formation by an operator during machining or on chips that were collected after the tests. However, in many cases, these methods cannot give us accurate quantitative differences for evaluation of the chip breakability of similar steel grades and similar sets of machining parameters. Thus, more sensitive methods are required to obtain more detailed information. In this study, a new method for the objective assessment of chip breakability based on quantitative determination of the weight distribution of chips (WDC) was tested and applied during machining of stainless steels without Ca treatment (316L) and with Ca treatment (316L + Ca). The obtained results show great consistencies and the reliability of this method. By using the WDC method, significant quantitative differences were obtained by the evaluation of chips, which were collected during the machining process of these two similar grades of steel at various cutting parameters, while, visually, these chips look very similar. More specifically, it was found that the Ca treatment of steel can improve the chip breakability of 316L + Ca steel in 80% of cutting trials, since a fraction of small light chips (Type I) from this steel increased and a fraction of large heavy chips (Type III) decreased accordingly. Moreover, the WDCs that were obtained at different cutting parameters were determined and compared in this study. The obtained results can be used for the optimization of chip breakability of each steel at different cutting parameters. The positive effect of Ca treatment of stainless steel was discussed in this study based on consideration of the modification of different non-metallic inclusions and their effect on the chip breakability during machining.

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Guo, Yang, Christopher Saldana, James B. Mann, Rachid M'Saoubi, and Srinivasan Chandrasekar. "Deformation and Microstructure in Machining." Advanced Materials Research 223 (April 2011): 325–31. http://dx.doi.org/10.4028/www.scientific.net/amr.223.325.

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Deformation history and state of chip and machined surface in low-speed cutting have been characterized using image analysis, complemented by microstructure and hardness. Fine scale details of the deformation field of relevance to machining modelling are highlighted. The severe plastic deformation inherent to chip formation results in microstructure changes which can be controlled through appropriate process parameters selected with the aid of machining simulations. Scaling of subsurface strain distribution is observed. Similarity in deformation history of chip and near-surface suggests opportunities for engineering surfaces with controlled deformation levels and microstructures, directly, by machining. The deformation characterization offers substantial scope for improvement and validation of machining models, and enhancement of machining process capability.

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Obikawa, T., H. Sasahara, T. Shirakashi, and E. Usui. "Application of Computational Machining Method to Discontinuous Chip Formation." Journal of Manufacturing Science and Engineering 119, no. 4B (November 1, 1997): 667–74. http://dx.doi.org/10.1115/1.2836807.

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A finite element modeling is developed to simulate and visualize the discontinuous chip formation in the orthogonal cutting of 60 percent Cu-40 percent Zn brasses. A ductile fracture criterion expressed as a function of strain, strain rate and hydrostatic pressure is applied to the crack growth from the tool tip to the chip free surface in the segmentation of discontinuous chips. Chip shape and the inclination of fracture surface produced in computational machining are in good agreement with those in actual machining. The visualization of the computational machining processes clarifies the mechanism of discontinuous chip formation. The influences of chip segmentation upon the residual stress and strain in the machined layer are also clarified quantitatively.

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Zhang, Peng, Xing Yu Guo, Kang Pei Zhao, and Li You Zhu. "Research on Chip Breaking Feature of the Micro Hole Vibration Drilling." Materials Science Forum 694 (July 2011): 616–19. http://dx.doi.org/10.4028/www.scientific.net/msf.694.616.

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It is often one of the most important issues for chip breaking and chip removal problems in the hole machining process, especially for micro hole. The chip breaking mechanism of the vibration drilling is researched, and its chip breaking conditions is analyzed. The micro drilling experiments are carried to contrast the chip shape of common drilling and vibration one. It can be draw that the vibration drilling can realize the regular chip breaking, which is beneficial to chip removal in hole machining, the chip breaking feature is one of the fine process effects. This work further enriches the vibration drilling technology.

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Lasukov, A. A., P. A. Chazov, and А. V. Barsuk. "Investigation on the Elemental Chip Formation Process in Hard-to-Machine Material Cutting." Applied Mechanics and Materials 682 (October 2014): 504–9. http://dx.doi.org/10.4028/www.scientific.net/amm.682.504.

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The mechanism of discontinuous chip formation has been studied less than the mechanism of continuous chip formation. However, when most modern materials having specific physical and mechanical properties are subject to machining, such processes are featured by discontinuous chip formation. The paper describes the basic dependencies of discontinuous chip parameters on machining modes. This is a trial undertaken to introduce an explanation of how the basic factors of the cutting process influence over parameters of chip formation.

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Guan, Jia Liang, Xin Qiang Ma, Cheng Guo Cao, Xiao Hui Zhang, and Lei Zhu. "Machining Mechanism of Fresnel Lens Mold." Advanced Materials Research 1027 (October 2014): 72–75. http://dx.doi.org/10.4028/www.scientific.net/amr.1027.72.

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This paper analyzed the large diameter Fresnel lens mold machining mechanism based on modal test methods .The design and mold machining principle of Fresnel lens were introduced . Explored the cutting speed and feed on chip formation process. The results show that: the material strength and plastic brittle have significant impact on chip morphology in the H62 brass mold processing, an improvement of material strength with the increase of strain rate and the evolution process of the chip can be divided into: ribbon cuttings, serrated chips, cell chips.

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Strenkowski, J. S., and S. M. Athavale. "A Partially Constrained Eulerian Orthogonal Cutting Model for Chip Control Tools." Journal of Manufacturing Science and Engineering 119, no. 4B (November 1, 1997): 681–88. http://dx.doi.org/10.1115/1.2836809.

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A partially constrained Eulerian finite element model for orthogonal machining with chip control tools is described. A new constrained free surface algorithm was developed in which the chip thickness was constrained to be uniform along the length of the chip. Using the model, the deformed chip shape and thickness, chip-tool contact, and the velocity, strain, stress, and temperature distributions can be determined. Simulations for machining of stainless steel 304 (SS 304) with obstruction and groove tools are presented. Good agreement was found, between measured and predicted tool forces and chip thicknesses.

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Mohd Hadzley, A. B., A. Siti Sarah, R. Izamshah, and M. R. Nurul Fatin. "The Study of Tool Wear Performance on Pocket Milling Strategy." Applied Mechanics and Materials 699 (November 2014): 64–69. http://dx.doi.org/10.4028/www.scientific.net/amm.699.64.

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The increasing productivity demand in machining industry has lead for fast material removal machining technique of pocket milling using different tool path strategies. This project aims to study about the effect of different tool path strategies on tool wear when machining aluminium alloy 7076. Five milling strategies were evaluated outward helical, inward helical, back and forth, offset on part one-way and offset on part zigzag. CATIA V5R19 was used to setup milling path and the machining experiments were carried out on a HAAS’ 3 axis CNC milling machine. The machining was held under wet condition with 2500 rpm cutting speed, 800 mm/min feed rate, 2 mm radial depth of cut and 2 mm axial depth of cut. The results showed that the best tool path strategies are inward helical and offset on part one-way, while the worst tool path strategy is outward helical. Failure to evacuate chip during pocket milling is the main reason to cause rapid tool wear due to temperature rise and higher contact time and area of cutting tool with the chip. Results from this experiment help to guide the machinist to perform pocket milling effectively.

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Fang, X. D., Y. J. Fang, and S. Hamidnia. "Computer Animation of 3-D Chip Formation in Oblique Machining." Journal of Manufacturing Science and Engineering 119, no. 3 (August 1, 1997): 433–38. http://dx.doi.org/10.1115/1.2831124.

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This paper presents details of developing a computer animation system for chip formation in oblique machining process. The 3-D chip animation model developed integrates chip flow equation, chip curling patterns, chip geometrical features and mathematical expression for 3-D helix surface. Based on the input conditions (chip breaker parameters and cutting conditions), a computer program is developed to convert the parametric prediction into a series of dynamic graphs demonstrating chip formation process. The methodology presented in this paper may provide an assistance for the machine operator to choose the machining conditions or for the process planning designer to evaluate the chip control effect.

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Mikhailov, Stanislav, Nikolai Kovelenov, and Pavel Burdin. "Modelling and controlling the process of cutting with complex-geometry tools to improve efficiency of mining machines and plants." E3S Web of Conferences 326 (2021): 00012. http://dx.doi.org/10.1051/e3sconf/202132600012.

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Constant quality improvement through automation of production processes is an important prerequisite for increased viability of mining machines and plants. Factors that limit the automation of the cutting machining operations include the problem of controlling the chip formation and chip crushing. Solution of this problem necessitates theoretical description of the material cutting conditions for tools with curvilinear surfaces. The paper describes basic principles of modeling the cutting process using complex-geometry tools with curvilinear rake. The theory is based on the concept of chip formation as a process of inhomogeneous strain in the plastic zone where the chip originates. Based on the analysis of the stress-strain state in the cutting zone, criterial relationships were derived that correlate the geometric parameters of the chip shape and machining conditions of the curvilinear-rake tool. Prerequisites for chip breaking are stability of the chip shape during cutting, stable chip-to-obstacle contact, high chip stiffness and low flexibility. The machining conditions leading to chip fragmentation could be found by solving the strength problem. Through establishing the cause-and-effect relationships of the processes of chip formation, curling and breaking, new approaches to achieving favorable chip shape may be found by exerting deliberate impact on the plastic zone of the chip formation through optimizing the conditions for the chip flow off the tool. The established relationships between the output parameters of the cutting process and process conditions of cutting with a complex-geometry tool offer the way to control the chip flow parameters in various machining operations. The research is aimed at creating scientifically informed design codes and optimization of cutting parameters for tools with curvilinear chip-curling and chip-breaking rake surfaces.

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He, Y., and Zheng Qiang Yao. "Comparative Experiments for Different End Mills of Indexable Inserts with 3-D Chip Breaker." Materials Science Forum 471-472 (December 2004): 775–78. http://dx.doi.org/10.4028/www.scientific.net/msf.471-472.775.

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End mills are very widely used in machining metal. In this paper, based on analysis of three different end milling indexable inserts with 3-D chip breaker, the influence of different chip breaker on cutting force, chip deformation and machined accuracy are studied by comparative experiments. The results show that the cutting effect of end mills with indexable inserts can be improved by optimization of 3-D chip breaker and suitable for different machining condition.

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Lin, Shen Yung, and S. H. Cheng. "Investigation of the Chip Types in High Speed Machining of SKD11 Steel." Key Engineering Materials 364-366 (December 2007): 1009–14. http://dx.doi.org/10.4028/www.scientific.net/kem.364-366.1009.

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High speed machining is very popular and widely used in industry recently, and it has been accepted as a key technology for die and mold steel manufacturing because it has much advantage as compared with conventional machining such as low cutting resistance, low cutting heat generation and high production rate, etc. The finite element method is utilized in this study to simulate the processes of chip formation during high speed machining of SKD11 die steel workpiece step by step from an incipient of tool-workpiece engagement to a steady state of chip formation. The effects of different combinations of cutting conditions such as cutting velocity, feed rate, rake angle and nose radius of the tool on the curly types of chip formation are investigated thoroughly for establishing the related skill for high speed machining or for predicting the chip morphology in advance.

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Recht, R. F. "A Dynamic Analysis of High-Speed Machining." Journal of Engineering for Industry 107, no. 4 (November 1, 1985): 309–15. http://dx.doi.org/10.1115/1.3186003.

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The dynamics of chip formation during high-speed orthogonal machining (planing) is examined. Merchant’s vector diagram of the forces acting upon the continuous chip free body is expanded to include inertial force components. Expressions are developed for cutting force and pressure. Energy balances are used to show that Merchant’s classical equation relating shear angle φ to rake angle α and friction angle τ applies, independent of cutting speed. Apparent differences between experimental observations of shear angle φ and Merchant’s prediction are attributed to workpiece material anisotropies, tool wear, built-up edge, and inaccurate measurement of the friction coefficient at the tool–chip interface. It is shown that good experimental values of the shear angle and friction coefficient may be obtained by measuring cutting pressure, utilizing dynamic material properties data, and invoking Merchant’s relation to resolve the energy balance. Continuous and segmented chip formation are contrasted. Melting in the tool–chip interface is verified.

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Jackson, Mark J., Jameson K. Nelson, Michael D. Whitfield, Jonathan S. Morrell, Rodney G. Handy, and Peter L. Schmidt. "Chip formation and similarity in the plano-grinding of explosive surrogates." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, no. 12 (January 6, 2017): 2071–82. http://dx.doi.org/10.1177/0954405416683972.

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The processing of polymer-bonded explosives is not widely reported in the literature, especially the machining of explosive surrogates in the combined planing and grinding operation known as plano-grinding. The process of machining long pieces of an inert substitute using a wax binder to hold sugar particles together and then subjecting the surrogate material to a linear cutting motion to generate chip fragments is described. The aim and purpose of this work is to analyze the machining of explosive surrogates in terms of chip formation models (oscillating and stress ratio models) and similarity models (chip compression ratio, Poletica, and Peclet numbers). The analysis of machining is compared to standard engineering materials so that the explosives engineer can benchmark machining performance of explosive surrogates to standard materials. The article concludes with statements on how to improve the understanding of machining of explosive surrogates with specifically engineered abrasive cutting tools.

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He, Yan Li, Hai Ying Ma, and Jing Yi Wang. "Chip Formation Simulation in FE Modeling for Machining FRP Composite." Advanced Materials Research 690-693 (May 2013): 2422–26. http://dx.doi.org/10.4028/www.scientific.net/amr.690-693.2422.

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The influence of chip formation technology on the simulation of machining unidirectional fiber reinforced polymer composite (FRP) is investigated. Two-dimensional macro-mechanical FE model was developed for orthogonal machining. Tsai-Hill failure criterion was implemented in VUMAT Abaqus subroutine. Two different chip formation technologies were simulated, analyzed and compared with experiment in literature. The results show that chip formation technology makes a difference in FRP machining simulation for various cutting conditions. Though chip shape, cutting forces and sub surface damages predicted by ALE model are more reasonable than that by element deletion model, predictions in both models are not satisfactory due to inherent limitations associated with the macro mechanical FE model and Tsai-Hill damage criterion.

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Wu, Bo, Yu Lin Yan, and Sebastian Münstermann. "Modelling of Chip Breakage in Machining Process with Damage Mechanics Model." Applied Mechanics and Materials 784 (August 2015): 411–18. http://dx.doi.org/10.4028/www.scientific.net/amm.784.411.

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Controlled chip breakage is important for machining process. In order to investigate the chip breakage behaviour in turning process, damage mechanics approach is applied in FE simulation of chip breakage. In this work, an advanced damage mechanics model is implemented for description of the plastic flow and damage behaviour of chip material in simulation. This material model takes the temperature, strain rate as well as state of stress into consideration, which are essential for application in machining processes.

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Naerheim, Yngve, Tennyson Smith, and Ming-Shong Lan. "Experimental Investigation of Cutting Fluid Interaction in Machining." Journal of Tribology 108, no. 3 (July 1, 1986): 364–67. http://dx.doi.org/10.1115/1.3261205.

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Scanning Auger analysis of fracture surfaces of chips from cutting 4340 steel bars and 4130 steel tubing using CCl4 as a model cutting fluid provide evidence that it is possible for cutting fluid or vapor to penetrate into the chip along fissures created during chip formation. Similar analysis of the rake face on the tools provide evidence of partial penetration between the tool and chip as well. The effect of the penetration is to reduce the energy required for the cutting process by facilitating the chip formation and reducing the adhesion forces between the tool and chip. The penetration can be explained by the capillary action of fissures that provide reactive surfaces and fast propagation paths for the cutting fluid and vapor.

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Stevenson, R. "The Morphology of Machining Chips Formed During Low Speed Quasi-Orthogonal Machining of CA 360 Brass and a Model for Their Formation." Journal of Engineering for Industry 114, no. 4 (November 1, 1992): 404–11. http://dx.doi.org/10.1115/1.2900691.

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In a previous study of orthogonal machining of CA 360 brass, periodic load fluctuations were related to geometric features observed on the machining chip. In this study, the metallography of these machining chips was examined using both optical and scanning electron microscopy with the goal of better understanding the cutting mechanism and the origin of the load fluctuations. It was determined that the load variations were associated with periodic variations in chip thickness, implying a periodic variation in shear angle. It is difficult to detect such a variation in shear angle using an etch to identify deformation patterns, but shear angle variations could be inferred from the chip morphology and from the distortion of the lead particles in the machining chip. A simple model is presented which exhibits periodic shear angle variations if deformation is assumed to occur in a shear zone of finite thickness and if the material’s workhardening capacity is exhausted at strains comparable with those developed during machining. Computations incorporating the features of this model are shown to accurately reproduce the pattern of the experimental observations.

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Yang, Xiang, Tobias Marx, Marco Zimmermann, Hans Hagen, and Jan C. Aurich. "Virtual Reality Animation of Chip Formation during Turning." Advanced Materials Research 223 (April 2011): 203–11. http://dx.doi.org/10.4028/www.scientific.net/amr.223.203.

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Virtual Reality (VR) technology allows the animation of machining operations. The kinematic of the machining operation and the geometry of the parts are allocated prevalently to VR using the Virtual Reality Modeling Language (VRML). In order to visualize the machining operation close to reality, the chip formation process needs to be animated as well. This paper presents the virtual reality animation of external cylindrical turning considering the chip formation and the results of the machining operation, such as the process forces. The chips are described numerically using JavaScript which is embedded into the VRML. The JavaScript accesses in addition to an experimentally generated database in order to display the results of the machining operation. The turning operation is visualized both in a non-immersive graphic user interface and an immersive Cave Automatic Virtual Environment (CAVE).

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Lee, Sun Kyu, S. H. Jang, Seok Woo Lee, and Hon Jong Choi. "Geometric Machining Mechanism of the Ultrasonic Drilling." Key Engineering Materials 339 (May 2007): 66–71. http://dx.doi.org/10.4028/www.scientific.net/kem.339.66.

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The application of an ultrasonic vibration is one of promising means in machining micro-holes. In this study, the differences of in the geometric machining mechanism between the ultrasonic and the conventional drilling were investigated. Specifically, the uncut chip thickness before machining and the tool trajectories of the cutting edges were formulated and compared with machining results. Through the machining experiments, it was found that those these parameters well matched with the appearance of both the disposed chips and the machined surface. Furthermore, the results indicated that the change of uncut chip thickness resulted in decreased machining resistance as well as improvement of the machined surface

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Liu, Er Liang, Rong Di Han, Guang Yu Tan, and Zhen Jia Li. "Analysis of Chip Breaking Prediction in Cutting Aluminum Alloys." Materials Science Forum 532-533 (December 2006): 213–16. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.213.

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As machining technology develops toward the unmanned and automated system, the prediction of chip breaking is considered increasingly important, especially in continuous machining such as in cutting aluminum alloys. In this paper, chip breakers with different parameters are designed to produce chips that can be evacuated easily and reliably from the working zone. The formulation of chip up-curl radius is constructed through analyzing the chips subject to chip breaker. The predictive model of chip breaking is developed based on chip breaking conditions. Chip breaking strain is obtained by using backward-deducing method and cutting experiments. In order to verify the model, PCD tools with chip breakers are used to cut LY12, chip breaking areas are compared with those obtained from the predictive model. Results show the chip breaking predictive model is reasonable.

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Cao, Ming Rang, Sheng Qiang Yang, Wen Hui Li, and Shi Chun Yang. "Chip-Ejection Mechanism and Experimental Study of Water Dispersant Dielectric Fluid on Small-Hole EDM." Advanced Materials Research 97-101 (March 2010): 4111–15. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.4111.

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The small hole EDM is one main method of micro holes machining and applied very widely. But it’s machining efficiency is low and machining stability is bad, which is more obvious because of chip-ejection difficulty when the ratio of length to diameter is rather large. Secondary discharge caused by chip-ejection difficulty not only makes the material removal rate reduce, but also causes geometric tolerance and affects product performance. Based on dispersion mechanism study of the water dispersant, the influence of the water dispersant is analyzed to chip-ejection, material removal rate and machining quality of the high-speed small-hole EDM. By contrasting the machining effect on using tap water with disperser dielectric liquid during electric spark small hole machining, adding the certain proportion disperser in water-based dielectric liquid may increase the material removal rate, decrease the tool wear rate, improve the effective impulse numbers, obviously reduce the second discharge number, and the taper of tool electrode and hole becomes small, so the hole machining quality enhances.

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Ding, X., L. C. Lee, David Lee Butler, and Kah Chuan Shaw. "Effects of Crystallographic Structure on Machining Performance with Polycrystalline Oxygen Free Copper by a Single Crystalline Diamond Micro-Tool." Key Engineering Materials 447-448 (September 2010): 31–35. http://dx.doi.org/10.4028/www.scientific.net/kem.447-448.31.

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A study was carried out to investigate effects of crystallographic structure on the machining performance with polycrystalline oxygen free copper (OFC) using a single crystalline diamond (SCD) micro-tool. The SCD micro-tool used in this study fabricated with a focused ion beam (FIB) has a cutting length of around 30 µm on the primary clearance face. It was found that a change in crystallographic orientation resulted in a variation in machining force, chip thickness and shear angle, leading to a change in machined surface integrity. When a micro-size tool traverses within a grain at a machining direction aligned with a particular crystallographic orientation, the work material in front of the machining tool is found to be severely deformed. If the orientation changes to a less favorable orientation, this may lead to a much reduced shear angle, a thicker chip, striation at the chip back, higher machining forces and a degraded machined surface. This study contributes to the understanding of the physics of micro scale mechanical machining (micro-machining).

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Gajrani, Kishor Kumar, Rokkham Pavan Kumar Reddy, and Mamilla Ravi Sankar. "Tribo-mechanical and surface morphological comparison of untextured, mechanical micro-textured (MμT), and coated-MμT cutting tools during machining." Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology 233, no. 1 (March 27, 2018): 95–111. http://dx.doi.org/10.1177/1350650118764975.

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In machining process, cutting fluids are used to reduce the tool–chip interface temperature and forces, but it causes various health hazards to machine operators as well as increases the associated costs. To improve machining sustainability, researchers are trying to reduce or eliminate cutting fluid usage during machining by various other techniques (development of better tool material, bio-cutting fluids, use of vegetable oils, near-dry machining, process optimization, surface coatings, etc). In recent years, several researchers applied controlled surface modification (surface texturing/engineering) at the tool–chip interface to improve the tribological properties in the machining performance. In the present study, first mechanical microtextures (MµT) are created on the rake surface, and its structural stability is compared with an untextured/virgin cutting tool. The static structural analyses show a negligible effect of mechanical microtextures on the strength of the cutting tool. Afterwards, MµT cutting tools are coated using molybdenum disulphide (MoS2) solid lubricant (i.e. coated MµT, C-MµT). Subsequently, the machining performance studies of C-MµT were carried out to show its advantages over two other types of cutting tools (UC, MµT). Performance of C-MµT is improved by mechanical microtextures (due to the reduction in the actual contact area between tool–chip interfaces) and proper lubrication of the tool–chip contact area. Thus, due to the reduced contact area and formation of lubricant layer by MoS2 at the tool–chip interface, C-MµT experiences 23.75% lower tool–chip interface temperature, 41.06% reduction in the cutting force, and produces 14.37% less workpiece center line average surface roughness ( Ra) compared to untextured cutting tool. C-MµT experiences 9.55% lower tool–chip interface temperature, 19.02% reduction in the cutting force, and produces 5.34% less workpiece center line average surface roughness compared to the MµT cutting tool. Hence, C-MµT cutting tools are the viable alternative to untextured cutting tools.

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Coy, Diana Carolina Gálvez, Pablo Andres Erazo Muñoz, Fernando Londoño Zapata, John Alexander Ortiz Torres, and Carloman Arcila Zuluaga. "MACHINING BY CHIP REMOVAL: BIBLIOMETRIC ANALYSIS, EVOLUTION, AND RESEARCH TRENDS." Journal of Southwest Jiaotong University 57, no. 3 (June 30, 2022): 336–46. http://dx.doi.org/10.35741/issn.0258-2724.57.3.27.

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This paper aims to acquaint the readers with the research trends in the area of machining by chip removal, which has been widely used as a process of component manufacturing in industry, through bibliometric analysis. In this paper, the review and the network analysis were obtained by tools such as Bibliometrix in R, VOSviewer, Sci2, and Gephi to identify the tree of science of the literature related to machining by chip removal. This review identified four main lines or clusters related to modeling of machining processes, machining processes, machining fluids, and machining surface monitoring. This allows teachers, researchers, and academicians interested in the topic to know its evolution and trends to guide subsequent research.

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Arcona, C., and Th A. Dow. "An Empirical Tool Force Model for Precision Machining." Journal of Manufacturing Science and Engineering 120, no. 4 (November 1, 1998): 700–707. http://dx.doi.org/10.1115/1.2830209.

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The accuracy of precision machining operations could be improved through tool force feedback. Tool force is ideally suited for use in a control algorithm because it contains information on the instantaneous depth of cut, feed rate and condition of the tool. A tool force model that could form the basis of this new control technique has been developed. By measuring the shear angle from micrographs of chip cross sections, equations for the forces due to chip formation and the friction between the chip and the tool have been written. Furthermore, the effects of elastic deformation of the workpiece (spring back) on chip formation and the measured forces, which can be significant in precision machining, have been included in the model. Machining experiments were conducted with a 0 deg rake diamond tool and four metals that are commonly diamond turned. For machining with newly lapped as well as worn tools, the calculated forces were in excellent agreement with the measured values for the array of workpiece materials.

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Wu, C. L., Z. R. Wang, and Wen Zhang. "Research of Formation Mechanics on Nanostructured Chips by Multi-Deformations Based on Finite Element Method." Advanced Materials Research 989-994 (July 2014): 352–55. http://dx.doi.org/10.4028/www.scientific.net/amr.989-994.352.

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Formation of chip is a typical severe plastic deformation progress in machining which is only single deformation stage. The rake angle of tool is governing parameter to create large strain imposed in the chip. Effect of rake angle and deformation times on effective strain, mean strain, strain variety and strain rate imposed in the chip are researched respectively. The result of simulation have shown that the chip with large strain and better uniform of strain along the longitudinal section of chip can be produced with negative rake angle at some lower cutting velocity by multi-deformations in large strain machining.

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Fang, X. D., J. Fei, and I. S. Jawahir. "A hybrid algorithm for predicting chip form/chip breakability in machining." International Journal of Machine Tools and Manufacture 36, no. 10 (October 1996): 1093–107. http://dx.doi.org/10.1016/0890-6955(96)00002-8.

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Słodki, Bogdan, Wojciech Zębala, and Grzegorz Struzikiewicz. "Turning Titanium Alloy, Grade 5 ELI, With the Implementation of High Pressure Coolant." Materials 12, no. 5 (March 6, 2019): 768. http://dx.doi.org/10.3390/ma12050768.

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In the machining of difficult-to-cut alloys, such as titanium-based alloys, the delivery of a cutting fluid with high pressure can increase machining efficiency and improve process stability through more efficient chip breaking and removing. Proper selection of machining conditions can increase the productivity of the process while minimizing production costs. To present the influence of cutting fluid pressure and chip breaker geometry on the chip breaking process for various chip cross-sections Grade 5 ELI titanium alloy turning tests were carried out using carbide tools, H13A grade, with a -SF chip breaker geometry under the cutting fluid pressure of 70 bar. Measurements of the total cutting force components for different cutting speeds, feeds, and cutting depth in finishing turning were carried out. The analysis of the obtained chips forms and the application area of the chip breaker have been presented. It was proved that for small depth of cut (leading to small chip cross-section) the cutting fluid pressure is the main cause of the chip breakage, since the insert chip breaker does not work. On the other hand, for bigger depths of cut where the chip breaker goes in action, the cutting fluid pressure only supports this process. For medium values of depths of cut the strength of chip is high enough so that the pressure of the cutting fluid cannot cause chip breaking. A chip groove is not filled completely so the chip breaker cannot play its role.

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Meng, Jianbing, Bingqi Huang, Xiaojuan Dong, Yizhong Hu, Yugang Zhao, Xiuting Wei, and Xiaosheng Luan. "Experimental Investigation on Ultrasonic Atomization Assisted Turning of Titanium Alloy." Micromachines 11, no. 2 (February 5, 2020): 168. http://dx.doi.org/10.3390/mi11020168.

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There are high cutting temperatures, large tool wear, and poor tool life in conventional machining, owing to the superior strength and low thermal conductivity of titanium alloy. In this work, ultrasonic atomization assisted turning (UAAT) of Ti6Al4V was performed with a mixed water-soluble oil-based cutting fluid, dispersed into tiny droplets by the high frequency vibration of a piezoelectric crystal. Different cutting speeds and two machining environments, dry and ultrasonic atomization assisted machining, were considered in the investigation of tool life, tool wear morphology, surface roughness, and chip morphology. In comparison with dry machining, UAAT shows lower tool wear and longer tool life due to the advantages of cooling and lubrication. Furthermore, better surface roughness, smoother chip edges, and shorter tool-chip contact length were obtained with UAAT.

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Hwang, Joon, and Eui-Sik Chung. "Cutting Force Adapted Control Application in Micropositioned Machining." International Journal of Automation Technology 3, no. 3 (May 5, 2009): 263–70. http://dx.doi.org/10.20965/ijat.2009.p0263.

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In the machining process, cutting force is a physical quantity well reflecting the process itself. Measured cutting force is used to identify the tool wear, surface roughness, chip formation, chatter stability and dynamic cutter runout problems. The cutting force linearity is used to measure and control the irregular cutting phenomena and machining process. We applied force-adaptive cutting control technology to evaluate chatter and real-time compensation for dynamic cutter runout. We proposed the concept of force-adaptive cutting control in the angle domain based upon proportional-integral control to control chip-load variation in machining. The micropositioning control of cutting tool or workpiece positioning using a low-friction sliding table and piezoelectric actuator changed the chip-load variation. Our results are expected to provide invaluable information in precision machining technology.

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Liu, Er Liang, Chao Zhang, and Hui Ping Zhang. "Study on the Chip-Breaking Behavior under the Concept of Equivalent Parameters for Complicated Groove Insert in 45 Cutting Steel." Key Engineering Materials 407-408 (February 2009): 473–77. http://dx.doi.org/10.4028/www.scientific.net/kem.407-408.473.

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Chip control is a major problem to be solved in automated machining system. It involves a total system to produce chips that can be evacuated easily and reliably from the working zone and can be disposed of efficiently. In order to realize those, prediction of chip-breaking in machining is one of effective methods. In this paper, to predict the chip breakage systematically, the equivalent parameters concept is used. Through presenting a study of the effect of complicated groove insert equivalent parameters on chip formation and breaking, a predictive model of chip-breaking is constructed. Finally, chip-breaking experiments are made and the tested results show that differential chip-breaking point’s ratio is fewer than five percent, so it proves that the chip-breaking predictive model is reasonable.

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Schaper, F., and B. Lengacker. "Segmented chip formation during machining under the influence of different atmospheres." Practical Metallography 59, no. 11 (October 23, 2022): 676–83. http://dx.doi.org/10.1515/pm-2022-0065.

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Abstract High temperatures and a pronounced segmented chip are characteristic of titanium machining processes. The formation of segmented chips induces an alternating high frequency mechanical load on the tool and thus promotes tool failure. The presence of oxygen triggers a multitude of chemical interactions during the chip forming process. However, the oxygen content’s impact during titanium machining, especially on the chip formation, is unknown. In order to draw conclusions on this process, the machining tests were carried out while varying the oxygen content. The thus produced chips were metallographically examined. The varying degree of segmentation could then be visualized by boundary etching and subsequently be evaluated.

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Matras, Andrzej, and Wojciech Zębala. "Machining Efficiency Increase when Nickel Based Alloy Machining." Solid State Phenomena 261 (August 2017): 22–27. http://dx.doi.org/10.4028/www.scientific.net/ssp.261.22.

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Paper presents some investigations, concerning simulation of the nickel based alloy machining. The aim of the research was an optimization of the cutting data for the purpose to increase the machining efficiency and stabilization of the tangential component of the total cutting force at the assumed level. A dedicated physical material model was built and then included to the simulation strategy. Authors demonstrated the influence of the feed rate optimization on the tangential component of the total cutting force value changes and the chip area and in this way the improvement of the cutting process.

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Jiang, Hongwan, Zhongwei Ren, Lin He, Sen Yuan, and Zhongfei Zou. "Forming process and evaluation of chip in machining of high-strength steel by an independent-developed microgroove turning tool." Science Progress 104, no. 3 (July 2021): 003685042110320. http://dx.doi.org/10.1177/00368504211032091.

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Chip morphology is one of the evaluation indexes of cutting performance of cutting tools, and chip forming process has a direct and important influence on chip morphology. High-strength steel 40CrMnMo is one of typical oil country tubular goods (OCTG) and difficult-to-cut materials, and its chip morphology represents the machining quality of OCTG. The chip forming process of a new independent-developed microgroove turning tool for turning oil country tubular goods 40CrMnMo is researched, combining machining experiments with theoretical analysis. Research results show that with the increase of cutting speed, the initial radius of curvature of the chip fluctuates slightly, but the overall trend is upward. However, the ultimate radius of curvature decreases and the chip’s radius ratio also decreases. The relative ideal chip can be obtained if the proper cutting velocity and feed rate are given. Chip morphology results from the comprehensive effect of the two processes: The fracture and separation process of the workpiece during passing through the shear deformation zone and the process of curling and breaking away of the chip after passing through the rake face of the tool. The research results have a certain guiding significance for controlling the cutting process of machining the other material with similar performance.

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H. AL-Khafaji, Mohanned Mohammed. "Neural Network Modeling of Cutting Force and Chip Thickness Ratio for Turning Aluminum Alloy 7075-T6." Al-Khwarizmi Engineering Journal 14, no. 1 (April 9, 2018): 67–76. http://dx.doi.org/10.22153/https://doi.org/10.22153/kej.2018.10.004.

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The turning process has various factors, which affecting machinability and should be investigated. These are surface roughness, tool life, power consumption, cutting temperature, machining force components, tool wear, and chip thickness ratio. These factors made the process nonlinear and complicated. This work aims to build neural network models to correlate the cutting parameters, namely cutting speed, depth of cut and feed rate, to the machining force and chip thickness ratio. The turning process was performed on high strength aluminum alloy 7075-T6. Three radial basis neural networks are constructed for cutting force, passive force, and feed force. In addition, a radial basis network is constructed to model the chip thickness ratio. The inputs to all networks are cutting speed, depth of cut, and feed rate. All networks performances (outputs) for all machining force components (cutting force, passive force and feed force) showed perfect match with the experimental data and the calculated correlation coefficients were equal to one. The built network for the chip thickness ratio is giving correlation coefficient equal one too, when its output compared with the experimental results. These networks (models) are used to optimize the cutting parameters that produce the lowest machining force and chip thickness ratio. The models showed that the optimum machining force was (240.46 N) which can be produced when the cutting speed (683 m/min), depth of cut (3.18 mm) and feed rate (0.27 mm/rev). The proposed network for the chip thickness ratio showed that the minimum chip thickness is (1.21), which is at cutting speed (683 m/min), depth of cut (3.18 mm) and feed rate (0.17 mm/rev).

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Journal articles on the topic 'Machining chip'

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