Статті в журналах: "A non-profile cutting tool"

1

Uchiyama, Fumihiro, Akihiko Tsuboi, and Takashi Matsumura. "Surface Profile Analysis in Milling with Structured Tool." International Journal of Automation Technology 13, no. 1 (January 5, 2019): 101–8. http://dx.doi.org/10.20965/ijat.2019.p0101.

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Novel end mills with micro-scale structures have recently been developed to promote cutting performances with cutting forces, chip controls, and tool wears. However, the surface profiles are formed corresponding to the structures on the tool edges. The surface finishes, therefore, are worse than those of cuttings with straight edges of the end mills. This paper discusses surface profiles in milling with the structured tool and the cutter axis inclination. An analytical model is presented to simulate the surface profiles for the tool edge shape, the cutting parameters and the cutter axis inclination. Because the surface profiles are controlled in the simulation, the optimum cutting parameters are determined to reduce the surface roughness. Micro-scale nicks were fabricated on polycrystalline diamond edges with a laser machine tool. The sizes and pitches of the nicks were controlled by the laser processing parameters. The cutting tests were conducted to measure the surface profiles. The presented surface profile model was validated by comparing the simulated and the measured surface roughnesses. The surface finish can be improved in milling with the cutter axis inclination in the optimum cutting parameters.

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2

Tretyak, Tatiana, Alexander Leonidovich Myronenko, and Sergii Aleksandrovich Myronenko. "Profiling of a shaped worm cutter for shaping gears with non-involute tooth profile." Bulletin of the National Technical University «KhPI» Series: Dynamics and Strength of Machines, no. 1 (December 31, 2021): 27–31. http://dx.doi.org/10.20998/2078-9130.2021.1.232702.

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Of the mechanical transmissions used in mechanical engineering, the most common are gears with an involute profile of the teeth flanks. Gears made up of such wheels have a number of advantages, but they also have a number of significant disadvantages. Therefore jne of the current trends is the study of gears with a complex non-involute profile of the teeth flank which have advantages over involute gears in a number of applications, as well as the development of tools for their processing. There are two ways of gear teeth cutting: the copying method and the rolling-in method. The rolling-in method has advantages. The profile of the tool working by the rolling-in method does not depend on the number of teeth of the gear being cut, therefore, the same tool can be used to cut gears with any number of teeth. The accuracy of a gear made by the rolling-in method is significantly higher than the accuracy of a gear made by the copying method. This is primarily due to the continuity of the rolling-in process. When cutting teeth by the rolling method, the tooth surface is formed as a result of processing with a tool, the cutting edges of which are the tooth profile of the mating rack or the tooth profile of the mating gear, and during processing the tool and the workpiece form a mating gear pair. The most common gear cutting tool is the hob cutter. For the machining of gear wheels with a non-involute tooth profile widely used in industry equipment is used. One of the options for a rolling gear cutting tool for shaping gear wheels with a non-involute tooth profile can be a shaped worm cutter. The article describes the method of profiling of the cutting part of shaped hob cutter for machining of gear wheels with normal accuracy. To solve the problem the unified mathematical base – the apparatus of multiparameter mappings of space – the unified structure of mappings for gears and a compact set of unified operators, parameters and functional connections is used.

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3

Ramji, B. R., H. N. Narasimha Murthy, and B. K. Deepak. "Performance Analysis of Cryogenically Treated HSS Profile Cutter by Experimental and FEA." Advanced Materials Research 816-817 (September 2013): 311–16. http://dx.doi.org/10.4028/www.scientific.net/amr.816-817.311.

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The main objective of the research was to study the effect of cryogenic treatment and double tempering on the tool life of HSS profile cutter in machining EN47 Spring Steel cutting tool components. TiAlN coated HSS profile cutters were cryogenically treated at-175 °C and double tempered at 200 °C. Milling exercises were carried out using un-treated and treated and double tempered tools on EN-47 spring steel reamer components at different machining conditions. The treated HSS profile cutter showed 40 % greater tool life than that of the un-treated in machining EN-47 spring steel components for making flutes. FEA for temperature profile of the cutting tools of the treated and non-treated was performed. Tool tip temperature for untreated and treated were found to be 22 °C and 20 °C respectively.

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4

Vu, Ngoc Thiem, Shinn Liang Chang, Jackson Hu, and Tacker Wang. "Computer Program in Visual Basic Language for Manufacture of Helical Cutting Tools." Advanced Materials Research 488-489 (March 2012): 813–18. http://dx.doi.org/10.4028/www.scientific.net/amr.488-489.813.

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The helical cutting tools have complex geometries. A rack cutter is the most economical tool that has been used for manufacturing helical cutting tool. In this paper, the computer program has been designed to evaluate the manufacture abilities following design concept and analyze the technical parameters of helical cutting tool. The program can simulate the sections of helical cutting tool and the rack cutter, analyze the clearance angle, relief angle, and width top of the helical cutting tool, and modify the rack cutter profile to show the helical cutting tool profile suitably. This program can predict the differences during manufacture process and give the best solution for economical consideration.

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5

Maruno, Kenji, Masaki Michihata, Yasuhiro Mizutani, and Yasuhiro Takaya. "Fundamental Study on Novel On-Machine Measurement Method of a Cutting Tool Edge Profile with a Fluorescent Confocal Microscopy." International Journal of Automation Technology 10, no. 1 (January 4, 2016): 106–13. http://dx.doi.org/10.20965/ijat.2016.p0106.

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We propose a novel, on-machine method of measuring the profile of the cutting edge of a tool by using the cutting fluid on the tool surface. Despite an environment of on-machine tool profile measurement, it is difficult to measure a cutting edge profile by using conventional optical methods due to interference from the cutting fluid on the tool surface. To overcome this problem, we propose a profile measurement method that uses confocal fluorescent detection from the cutting fluid on the tool surface. Moreover, for precise measurements, a method that corrects for the thickness of the cutting fluid is provided. Fluorescence from the surface of a silicon wafer coated with a fluorescent dye that is set horizontally as well as vertically to the optical axis of a developed fluorescent confocal microscope is detected. As a basic verification, the cutting edge profile of a milling tool with wear is measured using the proposed measuring and correction methods that employ a fluorescent dye. The results confirm that the proposed method can provide detailed measurements of a tool wear profile.

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6

Ямников, Александр, Aleksandr Yamnikov, Дмитрий Волков, and Dmitry Volkov. "Impact of cutting face profile angle upon shear deformation degree." Science intensive technologies in mechanical engineering 2, no. 6 (June 1, 2017): 14–20. http://dx.doi.org/10.12737/article_5928313a1d2191.50016044.

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It is established that cutting with gear-cutting and thread-cutting tools is not free that results in the increase of loading upon tool tips and their quick wear. The layers of metal cut are subjected to considerable shear deformation and also to other kinds of deformation. In this connection the wear character of a tool and its properties will change. There is considered a process of chip removal by trapezoidal and triangular cutters (as in case of metal cutting off with teeth of a hob may be used not three but two tool tips) and the impact of a cutting face profile angle upon a shear deformation degree is also considered. There are shown analytical dependences for the definition of angles of a chip flow, a relative shear, a deformation degree of a shear and a value of tangential stresses in the cutting area taking into account the influence of the strength of material machined, width and thickness of a layer cut and a friction factor. The dependences are checked up at cutting with a trapezoidal cutter.

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7

Denkena, Berend, Volker Böß, and Patryk Manuel Hoppe. "Optimization of Non-Cutting Tool Paths." Advanced Materials Research 223 (April 2011): 911–17. http://dx.doi.org/10.4028/www.scientific.net/amr.223.911.

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The focus of CAM systems is on effectively creating cutting tool paths. However, collision risk is very high on multi axes machines when performing non-cutting traverse moves. If available, CAM systems offer limited setting options for non-cutting tool moves. In this paper an approach is presented that allows to automatically generating non-cutting tool paths. Process planners will not only be released from developing and simulating time-consuming multi axes traverse moves. The automatically calculated traverse moves will also machine-specifically optimized with respect to various optimization criteria.

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8

KHAJORNRUNGRUANG, Panart, Keiichi KIMURA, Hiroshi SUZUKI, and Keisuke SUZUKI. "1516 Non-Contact Micro Cutting Tool Diameter Measurement using Laser Diffraction." Proceedings of International Conference on Leading Edge Manufacturing in 21st century : LEM21 2015.8 (2015): _1516–1_—_1516–4_. http://dx.doi.org/10.1299/jsmelem.2015.8._1516-1_.

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9

Dong, Liang, Ai Bing Yu, Hao Wang, and Lei Wu. "Wear Analysis for Non-Smooth Surface HSS Cutting Tools." Applied Mechanics and Materials 101-102 (September 2011): 1035–38. http://dx.doi.org/10.4028/www.scientific.net/amm.101-102.1035.

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In order to improve cutting tool wear resistance, non-smooth surface was applied on HSS cutting tool and finite element method was used to analyze the wear of non-smooth surface HSS cutting tools. The orthogonal simulation test was established to analyze the influence of parameters on tool wear and the relationship between parameters and tool wear was discussed. Simulation results show that non-smooth surface could significantly improve the wear resistance of cutting tool. The line space has the most influence on cutting tool wear. The ranking of parameter influence on tool wear are line spacing, pit diameter and column spacing. And the lower tool wear usually occurs at points of pit line space which is three times as pit diameter.

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10

Bai, Da Shan, Jian Fei Sun, Kai Wang, and Wu Yi Chen. "Diffusion Behavior and Wear Mechanism of WC/Co Tools when Machining of Titanium Alloy." Solid State Phenomena 279 (August 2018): 60–66. http://dx.doi.org/10.4028/www.scientific.net/ssp.279.60.

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In this paper, fine-grain WC/Co tools were utilized in dry turning of the Ti-6Al-4V alloy. The wear modes of the cutting tools at different cutting speeds were analyzed. The diffusion behavior between the cutting tool and the workpiece was studied in detail based on the Auger electron spectroscopy (AES) depth profile technology. The diffusion wear mechanism was revealed. The results showed that the diffusion layer formed at the interface between the cutting tool and the adhering material. The diffusion ability of C was the strongest, followed by W, the weakest was Co in all the elements of the cutting tool. The chemical reactions took place close to the adhering material, forming the reaction layer. As a diffusion barrier, it was possible to limit the elements diffusion from the cutting tool to the adhering material, decrease the changes in the cutting tool composition and damages. The diffusion layer, which was weakened by diffusion, was worn off and taken away by the fast flowing chip during the cutting process, causing the diffusion wear characterized by a smooth crater formation on the tool surface.

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11

Prabhu, S., S. Karthik Saran, Debabrata Majumder, and Putti Venkata Siva Teja. "A Review on Applications of Image Processing in Inspection of Cutting Tool Surfaces." Applied Mechanics and Materials 766-767 (June 2015): 635–42. http://dx.doi.org/10.4028/www.scientific.net/amm.766-767.635.

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The increase in demand for industrial automation in the manufacturing industry has exposed the significance of machine vision in quality inspection and process monitoring. Contrast to stylus instruments, the computer vision systems have the advantages of being non-contact. In the present study a novel technique has been reviewed to explore various applications of Image processing in inspection of cutting tool surfaces. Measurement and inspection of Surface roughness, Tool wear, Tool profile, Thickness of coating done on tool and Surface defects are all reviewed in this paper which will help in developing a specialized inspection system particularly for inspection of machining tools alone in reduced production cost and minimised time.

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12

Chang, S.-L., and H.-C. Tseng. "Design of a novel cutter for manufacturing helical cutting tools." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 219, no. 4 (April 1, 2005): 395–408. http://dx.doi.org/10.1243/095440605x16901.

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Owing to the complex geometry of helical cutting tools, several manufacturing processes are required to produce the profile of the cutter and the cutting angles. If the traditional method of manufacture were used, the cost would be frustratingly expensive. In this paper, a novel straight-sided hob cutter design consisting of two curved cutting edges and three straight cutting edges with different pressure angles is proposed. By applying designed rake profile equations of a hob cutter, the principle of coordinate transformation, the theory of differential geometry, and the theory of gearing, a mathematical model of the helical cutting tool is derived. In addition, the cutting angles, the condition of full undercutting, and the width of the top land of the cutter are also studied. The novelty of the design is such that the multiangles of the helical cutting tool can be manufactured in one hobbing process, thereby simplifying the manufacturing process. The results and concepts proposed in the paper will be beneficial as design guidance for tool designers, will enhance the manufacturing processes of helical cutting tools, and will assist tool-related industries in upgrading their technology and competitiveness.

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13

Boca, Mihai, Mihaita Horodinca, and Marian-Octavian Andronic. "Proposing a method for estimating the real micro profile of a milling tool." MATEC Web of Conferences 178 (2018): 01007. http://dx.doi.org/10.1051/matecconf/201817801007.

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Manufacturing Engineering domain generally uses for creating virtual work piece profiles or tool representations descriptive parameters or simplified drawings. More recent and accurate methods such as the present study uses optical devices for obtaining virtual projections of work pieces/tools. This paper presents an experimental method applied in order to obtain the profile for a given cutting tool, which can offer in addition possibility to estimate the cutting tool wear, without using such built-in machine-tool device. The experimental values obtained are materialized by the accuracy which characterizes the accurate profile of the measured cutting tool. This fact can make a difference between a classical measurement method applied outside of machine tool sector and a new one provided by a device which offers the solution to measure a work piece directly on the machine tool, without modifying the actual work piece orientation conditions and at a low price.

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14

Kibbou, Dellagi, Majdouline, and Moufki. "Prediction of Surface Quality Based on the Non-Linear Vibrations in Orthogonal Cutting Process: Time Domain Modeling." Journal of Manufacturing and Materials Processing 3, no. 3 (June 26, 2019): 53. http://dx.doi.org/10.3390/jmmp3030053.

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This work presents an analysis of relationships between the non-linear vibrations in machining and the machined surface quality from an analytical model based on a predictive machining theory. In order to examine the influences of tool oscillations, several non-linear mechanisms were considered. Additionally, to solve the non-linear problem, a new computational strategy was developed. The resolution algorithm significantly reduces the computational times and makes the iterative approach more stable. In the present approach, the coupling between the tool oscillations and (i) the regenerative effect due to the variation of the uncut chip thickness between two successive passes and/or when the tool leaves the work (i.e., the tool disengagement from the cut), (ii) the friction conditions at the tool–chip interface, and (iii) the tool rake angle was considered. A parametric study was presented. The correlation between the surface quality, the cutting speed, the tool rake angle, and the friction coefficient was analyzed. The results show that, during tool vibrations, the arithmetic mean deviation of the waviness profile is highly non-linear with respect to the cutting conditions, and the model can be useful for selecting optimal cutting conditions.

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15

Sredanovic, Branislav, and Gordana Globocki Lakic. "Experimental Study on Micro-Machinability of Hardened Tool Steel in Profile Micro-Milling." Solid State Phenomena 261 (August 2017): 85–92. http://dx.doi.org/10.4028/www.scientific.net/ssp.261.85.

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Components miniaturization in industry leads to intensive research and development of efficient micro-technologies through research of different production processes, machines and tools. This paper presents experimental research on machinability of inclined surfaces on hardened steel workpieces with long-neck micro-end-ball mills. Workpiece is hardened AISI D2 tool steel (X155CrVMo-5). Micro-parts of this material is usually produced by non-conventional technologies such as electro-discharge machining (EDM) and laser beam machining (LBM), that allows machining of 2D or simple 3D structures. The effects of geometrical and cutting parameters on output machinability parameters in ball micro-milling were evaluated. Analysis of tool deflection, surface roughness and tool wedge wear was performed, in order to obtain the recommended cutting parameters for more precise, accurate and quality of micro-parts.

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16

Li, Qinghua, Chen Pan, Yuxin Jiao, and Kaixing Hu. "Investigation on Cutting Performance of Micro-Textured Cutting Tools." Micromachines 10, no. 6 (May 28, 2019): 352. http://dx.doi.org/10.3390/mi10060352.

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This paper explores the influence of micro textures on cutting performance of polycrystalline cubic boron nitride (PCBN) tools from two aspects, that is, tool wear and machined surface roughness. By designing micro-hole textures with different forms and scales on the rake face of tools when PCBN tools turn hardened steel GCr15, and combining finite element analysis (FEA) technology and cutting experiments, the cutting performance of micro-textured tools is simulated and analyzed. This paper analyses the influence of micro textures on tool wear and machined surface roughness by analyzing cutting force, Mises stress and maximum shear stress of tool surface. Results of finite element analysis (FEA) and cutting experiments show that the reasonable micro-hole textures can significantly alleviate tool wear and improve machined surface quality when compared with the non-textured tools. Besides, the size of micro-hole textures on the rake face play an important role in reducing the cutting force and tool wear. This is mainly because micro-hole textures can reduce cutting force and improve tool surface stress. Finally, by designing reasonable micro-hole textures on the rake face, the problems of bad roughness of machined workpiece and severe tool wear of PCBN tools in cutting GCr15 material are solved. Consequently, the paper shows that micro-hole textures have a positive effect on improving the cutting performance of tool.

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17

Zheng, Kairui, Fazhan Yang, Na Zhang, Qingyu Liu, and Fulin Jiang. "Study on the Cutting Performance of Micro Textured Tools on Cutting Ti-6Al-4V Titanium Alloy." Micromachines 11, no. 2 (January 25, 2020): 137. http://dx.doi.org/10.3390/mi11020137.

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Titanium alloys are widely used in various fields, but their machinability is poor because the chip would easily adhere to the tool surface during cutting, causing poor surface quality and tool wear. To improve the cutting performance of titanium alloy Ti-6Al-4V, experiments were conducted to investigate the effect of micro textured tool on the cutting performances. The cemented carbide tools whose rake faces were machined with line, rhombic, and sinusoidal groove textures with 10% area occupancy rates were adopted as the cutting tools. The effects of cutting depth and cutting speed on feed force and main cutting force were discussed based on experimental results. The results show that the cutting force produced by textured tools is less than that produced by non-textured tools. Under different cutting parameters, the best cutting performance can be obtained by using sinusoidal textured tools among the four types of tools. The wear of micro textured tools is significantly lower than that of non-textured tools, due to a continuous lubrication film between the chip and the rake face of the tool that can be produced because the micro texture can store and replenish lubricant. The surface roughness obtained using the textured tool is better than that using the non-textured tool. The surface roughness Ra can be reduced by 35.89% when using sinusoidal textured tools. This study is helpful for further improving the cutting performance of cemented carbide tools on titanium alloy and prolonging tool life.

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18

NARESH, Hazari, and Padhy CHINMAYA PRASAD. "Lathe Parameters Optimization for UD-GFRP Composite Part Turning with PCD Tool by Taguchi Method." INCAS BULLETIN 12, no. 4 (December 4, 2020): 135–44. http://dx.doi.org/10.13111/2066-8201.2020.12.4.12.

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The aerospace and automobile sectors are widely utilized the polymer composites. The composite materials, like unidirectional glass fiber reinforced polymer (UD-GFRP), is difficult to machine due to its anisotropic that is non-homogeneous character and such material requires special cutting tools. The proposed work is going to examine the tool wear, quality of the surface and forces generated in the various stages of inputs given to the machining of unidirectional glass fiber reinforced polymer (UD-GFRP) composites. The assessment of the machining incorporates tool wear investigations, surface roughness investigations and quality of material by varying input parameters. The Taguchi optimization technique with experimental design of L9 orthogonal array employed. The parameters range identified by trail runs and observations of conducted machining utilized for optimization. The Turning process parameters of cutting velocity or speed, rate of tool movement or feed rate and cutting depth on composite part or depth of cut were considered. The other factors, like tool material i.e., Poly-Crystalline Diamond (PCD) tool, its cutting regime (dry), profile of cutting tool are considered as constant parameters. The responses, like tool wear, surface finish, and cutting force, were measured against various input parameters, while machining the composite (UD-GFRP) composite part. The objective of this research is to establish relationship among various operating parameters to achieve desired results. That is major focus of the work on the economic condition for getting better values based on setting of input parameters.

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19

Hamidon, Roshaliza, Erry Y. T. Adesta, Muhammad Riza, and Mohammad Iqbal. "Effect of Cutting Parameters on Cutting Forces for Different Profile of Cutting." Applied Mechanics and Materials 799-800 (October 2015): 361–65. http://dx.doi.org/10.4028/www.scientific.net/amm.799-800.361.

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In machining operation of mould cavities, the tool travels in various straight and corner profiles following predetermined toolpath. Such condition results in a fluctuation of cutting forces that may produce bad surface finish. The objective of this study is to investigate the most influential parameters on cutting operation for both straight and corner profiles of pocketing operation. Cutting speeds of 150, 200 and 250m/min, feedrates from 0.05, 0.1, 0.15 mm/tooth and depths of cut of 0.1, 0.15 and 0.2 mm were selected for the cutting processes. Taguchi L9 orthogonal array with Pareto ANOVA analysis was employed to analyze the effects of the selected parameters. The result demonstrates there are different effects of cutting parameters on cutting forces for straight and corner profiles. Furthermore, it was found that cutting speed and feedrate are prevailing factors that affected cutting forces for both types of profile.

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20

Kiss, Dániel, and Gergő Mihályi. "Conceptional cutting tool design for internal thread turning." Design of Machines and Structures 10, no. 2 (2020): 41–48. http://dx.doi.org/10.32972/dms.2020.012.

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This article describes the different machining methods of the ball nut thread. One of the disadvantages of machining high pitch ball nuts by grinding process is to produce a modified tool profile to avoid collisions between the tool holder and the workpiece. However, by using profiled lathe inserts, it is possible to produce the thread profile of the ball nut using turning technology. The applicability of the technology is verified by tooling and experimental machining based on conceptual designs, the results of which are described at the end of the article.

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21

Janásek, Adam, Robert Čep, Pavel Nováček, Jiří Schreier, Vlastimil Ligocki, and Vladimír Vrba. "Sleeves’ Cutting Tool-Life Tests for Ceramic Inserts." Technological Engineering 10, no. 1 (December 1, 2013): 6–8. http://dx.doi.org/10.2478/teen-2013-0002.

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Abstract The article is focused on the experimental determination of tool-life for ceramic tool. Nowadays, machining with indexable ceramic cutting inserts can reduce manufacturing cost, if the cutting tool and the machine tool are designed to compliment each other. With the development of modern ceramic tool materials, they are more and more widely used in the field of metal cutting since their mechanical properties and cutting performances have been greatly improved in last decades. On the basis of previous tests the tool-wear was measured at constant cutting parameter which is more typical for High Volume Manufacturing Processes. The tested material, cast iron 25P, is used at car’s engine. The main aim of this article was to find out the performance for this material by arithmetic tolerance of Ra profile, the greatest height of Rz profile and the external diameter D and its connection.

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22

Liu, Yue, Zhanqiang Liu, Wentong Cai, Yukui Cai, Bing Wang, and Guoying Li. "Optimisation of Planning Parameters for Machining Blade Electrode Micro-Fillet with Scallop Height Modelling." Micromachines 12, no. 3 (February 26, 2021): 237. http://dx.doi.org/10.3390/mi12030237.

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Aero-engine blades are manufactured by electroforming process with electrodes. The blade electrode is usually machined with five-axis micromilling to get required profile roughness. Tool path planning parameters, such as cutting step and tool tilt angle, have a significant effect on the profile roughness of the micro-fillet of blade electrode. In this paper, the scallop height model of blade electrode micro-fillet processed by ball-end milling cutter was proposed. Effects of cutting step and tool tilt angle the machined micro-fillet profile roughness were predicted with the proposed scallop height model. The cutting step and tool tilt angle were then optimised to ensure the contour precision of the micro-fillet shape requirement. Finally, the tool path planning was generated and the machining strategy was validated through milling experiments. It was also found that the profile roughness was deteriorated due to size effect when the cutting step decreased to a certain value.

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23

Pilc, Jozef, Michal Sajgalik, Dana Stancekova, Miroslav Janota, and David Pitela. "Milling Of Shaped Grooves – Profile Of Form Tools." Technological Engineering 12, no. 2 (December 1, 2015): 31–33. http://dx.doi.org/10.1515/teen-2015-0016.

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Abstract This paper deals with design of milling tool for milling of shaped groove. Actual industry production requires the large amount of tools and notably the special tools used for example when shaped milling. The requirements on the quality of tools are increasingly demanding. The quality of tools is given by construction, production process, selected material and also heat treatment. Shaped milling requires special tools made for given shape. Main request on the construction of tool is making of shape of cutting edge, which can produce the required shape of workpiece.

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24

Dong, Liang, Cong Li, and Shu Hui Li. "Optimizing Design of the Cutting Tool in Cutting of Ultra-High Strength Steel Beam Part." Materials Science Forum 920 (April 2018): 120–25. http://dx.doi.org/10.4028/www.scientific.net/msf.920.120.

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In this research, the cutting process of a martensitic Ultra-High Strength Steel (UHSS) beam is investigated by using finite element method. The Modified Mohr-Coulomb fracture criterion (MMC) is employed in numerical simulation to calculate the ductile fracture during the process evolution. Tensile specimens are designed to obtain various stress states in tension. Equivalent fracture strains are measured with Digital Image Correlation (DIC) equipment to constitute the fracture locus. Based on the simulation, the local load situation of wear serious areas of the cutting tool is studied and the wear reason is explained. Optimizing design scheme for the tool profile is proposed to improve the tool wear. The optimized cutting tool is adopted in the actual industrial production and the wear life cycle is improved up to 14000 times cutting frequency compared with 4000 times cutting frequency for the original tool. The practice results demonstrate that the optimizing design scheme for the tool profile is very successfully.

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25

Zhao, Wen Hui, Zhen Yun Duan, Wen Zhen Zhao, and She Liu. "Study on On-Machine Measurement of Rotating Tools Based on Image Processing." Advanced Materials Research 97-101 (March 2010): 2678–81. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.2678.

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It is necessary to develop an on-machine measurement system of cutting tools with high precision and high efficiency on the NC machining, so that it can decrease non-production time and improve machining efficiency. A system for high precision measurement of rotating tools on the basis of image processing is described in this paper. Images are acquired from a digital camera and transmitted into a computer. The working profile of rotating tools and geometrical parameters are extracted accurately through image processing technology. Depending on theoretical analysis and experiments, this system can be widely applied to tool offset and NC programming based on working profile of the tools.

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26

Dos’Santos, Thomas, Christopher Thomas, Alistair McBurnie, Thomas Donelon, Lee Herrington, and Paul A. Jones. "The Cutting Movement Assessment Score (CMAS) Qualitative Screening Tool: Application to Mitigate Anterior Cruciate Ligament Injury Risk during Cutting." Biomechanics 1, no. 1 (April 6, 2021): 83–101. http://dx.doi.org/10.3390/biomechanics1010007.

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Side-step cutting is an action associated with non-contact anterior cruciate ligament (ACL) injury with a plethora of negative economical, health, and psychological implications. Although ACL injury risk factors are multifactorial, biomechanical and neuromuscular deficits which contribute to “high-risk” and aberrant movement patterns are linked to ACL injury risk due to increasing knee joint loads and potential ACL loading. Importantly, biomechanical and neuromuscular deficits are modifiable; thus, being able to profile and classify athletes as potentially “high-risk” of injury is a crucial process in ACL injury mitigation. The Cutting Movement Assessment Score (CMAS) is a recently validated field-based qualitative screening tool to identify athletes that display high-risk postures associated with increased non-contact ACL injury risk during side-step cutting. This article provides practitioners with a comprehensive and detailed overview regarding the rationale and implementation of the CMAS. Additionally, this review provides guidance on CMAS methodological procedures, CMAS operational definitions, and training recommendations to assist in the development of more effective non-contact ACL injury risk mitigation programmes.

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27

Fang, Ming Hui. "Numerical Algorithm of Tooth Profile of Noncircular Gear Pair." Applied Mechanics and Materials 201-202 (October 2012): 194–97. http://dx.doi.org/10.4028/www.scientific.net/amm.201-202.194.

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According to the generating method theory, noncircular gear with all convex pitch curve can be processed by generating, author designed noncircular gear tooth profile, described a method of precisely calculating noncircular gear tooth profile. And proposed automatically optimizes the noncircular gear tooth profile meshing curve part separately by the identical rack cutting tool different side envelope. Through rack cutting tool along two gear center of rotation segment deviation pitch curve change modified quantity to avoid tooth undercut, realization nonzero modified. The driving gear and the driven gear tooth profile meshing curve part separately by the identical rack cutting tool different side envelope, guarantees when meshing zero clearance. The noncircular gear machined by this method has been used in real machine, which verifies the feasibility of the method.

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28

Maruno, Kenji, Masaki Michihata, Yasuhiro Mizutani, and Yasuhiro Takaya. "On-Machine Measurement of Cutting Tool Edge Profile by Detecting Fluorescence from Cutting Fluid." MATEC Web of Conferences 32 (2015): 03003. http://dx.doi.org/10.1051/matecconf/20153203003.

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29

Kudryashov, E. A., and I. M. Smirnov. "CUTTING TOOL EQUIPMENT OF TURNING SURFACES OF A COMPLEX PROFILE." Professor’s Journal. Series: Technical science 1 (February 20, 2019): 20–30. http://dx.doi.org/10.18572/2686-8598-2019-1-1-20-30.

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30

Ivchenko, Oleksandr, Vitalii Ivanov, Justyna Trojanowska, Dmytro Zhyhylii, Olaf Ciszak, Olha Zaloha, Ivan Pavlenko, and Dmytro Hladyshev. "Method for an Effective Selection of Tools and Cutting Conditions during Precise Turning of Non-Alloy Quality Steel C45." Materials 15, no. 2 (January 10, 2022): 505. http://dx.doi.org/10.3390/ma15020505.

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The paper presents a constructing methodology for a modern approach to tools selection and solving the problem of assigning optimal cutting parameters for specific production conditions. The mathematical formulation determining the extreme values of the technological process optimality criteria is obtained. A system of technical and economic quality indicators for cutting tools is proposed. This system allows principles’ implementation of decentralization and interoperability “Industry 4.0” via finite element modeling of the cutting process based on solving the problem of orthogonal free cutting modeling. The proposed methodology further usage is possible by creating a standardized database on the parameters of the tool: the adhesive component of the friction cutting coefficient for processing of a specific pair of cutting and tool materials (or tool coating material) and the impacts of the cutting-edge radius on cutting efficiency of a particular material.

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31

WARDENAAR, E. C. P. "A NEW HAND TOOL FOR CUTTING SOIL MONOLITHS." Canadian Journal of Soil Science 67, no. 2 (May 1, 1987): 405–7. http://dx.doi.org/10.4141/cjss87-036.

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A portable tool for cutting undisturbed soil monoliths has been developed and field tested. A soil column suitable for mounting or subsampling can be obtained in less than 5 min from all soils that are not excessively stony. Key words: Profile cutter, undisturbed samples

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32

Xie, L. J., D. Zheng, C. Schmidt, and J. Schmidt. "Estimate of Tool Wear in Milling Operation Based on “Differential” Wear Rate Model." Applied Mechanics and Materials 10-12 (December 2007): 786–90. http://dx.doi.org/10.4028/www.scientific.net/amm.10-12.786.

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Many research show that in metal cutting process wear rate is dependent on the cutting process variables such as temperature at tool face, contact pressure (normal stress) and relative sliding velocity at tool/chip and tool/work interface; their relationship is described by “differential” wear rate model. Based on this “differential” wear rate model, a method to estimate tool wear in milling operation is proposed and the cutting process variables are predicted by performing chip formation analysis with FEM code ABAQUS/Explicit and heat transfer analysis with ABAQUS/Standard. The implementation is exemplified by estimating tool wear of carbide tools in milling of Ck45 work. Both progressive flank wear and crater wear profile are estimated.

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33

Tang, Qian, Di Yan, and Yao Kun Bi. "Research on Calculation Method of the Cutter Setting Angle in Screw Surface Form Milling." Advanced Materials Research 472-475 (February 2012): 1023–27. http://dx.doi.org/10.4028/www.scientific.net/amr.472-475.1023.

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The transition surface and the over-cutting phenomenon always appear in the screw surface form milling process which is based on the non instantaneous center envelope method. To solve this problem, an accurate calculation method of the cutter setting angle is proposed. The contact equation between cutter and workpiece is introduced. Spatial mathematical model is established according to the cutting tool profile calculation principle and the cutting mechanism. This method improves machining precision effectively, and can get the required screw surface. It also provides essential references for the design of form milling cutter.

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34

Ali, Shafahat, Said Abdallah, and Salman Pervaiz. "Predicting Cutting Force and Primary Shear Behavior in Micro-Textured Tools Assisted Machining of AISI 630: Numerical Modeling and Taguchi Analysis." Micromachines 13, no. 1 (January 7, 2022): 91. http://dx.doi.org/10.3390/mi13010091.

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The cutting tool heats up during the cutting of high-performance super alloys and it negatively affects the life of the cutting tool. Improved tool life can enhance both the machinability and sustainability of the cutting process. To improve the tool life preferably cutting fluids are utilized. However, the majority of cutting fluids are non-biodegradable in nature and pose harmful threats to the environment. It has been established in the metal cutting literature that introducing microgrooves at the cutting tool rake face can significantly reduce the coefficient of friction (COF). Reduction in the COF promotes anti-adhesive behavior that improves the tool life. The current study numerically investigates the orthogonal cutting process of AISI 630 Stainless Steel using different micro grooved cutting tools. Results of the numerical simulations point to the positive influence of micro grooves on tool life. The results of the main effects found that the cutting temperature was decreased by approximately 10% and 7% with rectangular and triangular micro grooved tools, respectively. Over machining performance indicated that rectangular micro groove tools provided comparatively better performance.

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35

Yue, Caixu, Xianli Liu, Yunpeng Ding, and Steven Y. Liang. "Off-line error compensation in corner milling process." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, no. 7 (September 1, 2016): 1172–81. http://dx.doi.org/10.1177/0954405416666901.

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Tool deflection induced by cutting force could result in dimensional inaccuracies or profile error in corner milling process. Error compensation has been proved to be an effective method to get accuracy component in milling process. This article presents a methodology to compensate profile errors by modifying tool path. The compensation effect strongly depends on accuracy of the cutting force model used. The mathematical expression of chip thickness is proposed based on the true track of cutting edge for corner milling process, which considers the effect of tool deflection. The deflection of tool is calculated by finite element method. Then, an off-line compensation algorithm for corner profile error is developed. Following the theoretical analysis, the effect of the error compensation algorithm is verified by experimental study. The outcome provides useful comprehension about selection of process conditions for corner milling process.

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36

Asai, Takemi, Sayeda Ferdous, Yoshikazu Arai, Yi Yang, and Wei Gao. "On-Machine Measurement of Tool Cutting Edge Profiles." International Journal of Automation Technology 3, no. 4 (July 5, 2009): 408–14. http://dx.doi.org/10.20965/ijat.2009.p0408.

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An on-machine profile measuring system for diamond cutting tools was constructed. It is based on the atomic force microscope (AFM). The characteristics evaluation experiment of the AFM unit was carried out. On-machine measurements of three tools, one having a straight cutting edge and the other two having round edges with nose radii of 0.2 mm and 0.1 mm, respectively, were conducted to demonstrate the applicability of this system.

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37

Čerče, Luka, Davorin Kramar, and Janez Kopac. "IN-LINE SPATIAL MONITORING OF CUTTING TOOL-WEAR." International Journal "Advanced Quality" 44, no. 1 (February 21, 2017): 41. http://dx.doi.org/10.25137/ijaq.n1.v44.y2016.p41-46.

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The tool-wear of cutting tools has a very strong impact on the product quality as well as efficiency of the machining processes. Despite the nowadays high automation level in machining industry, tool -wear diagnostic that is measured of the machine tool, still prevent complete automation of the entire machining process. Therefore, its in line characterization is crucial. Thus the paper presents developed innovative, robust and reliable direct measuring procedure for measuring spatial cutting tool-wear in-line, with the usage of laser profile sensor. The technique provides possibility for determination of 3D wear profiles, as advantage to currently used 2D subjective techniques (microscopes, etc.). The use of proposed measurement system removes the subjective manual inspection and minimizes the time used for wear easurement. In the manuscript the system is experimentally tested on a case s tudy, with further in-depth performed analyses of spatial cutting tool-wear.

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38

Wang, Bin, Jia Yang Zhang, Chun Ling Wu, and Wen Jun Deng. "A Numeric Investigation of Rectangular Groove Cutting with Different Lateral Micro Textured Tools." Key Engineering Materials 693 (May 2016): 697–703. http://dx.doi.org/10.4028/www.scientific.net/kem.693.697.

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Micro textures on the tool rake face facilitate to improve friction conditions at the tool-chip interface, and therefore contribute to decreasing cutting force and cutting temperature. Literature has shown that lateral textures (perpendicular to chip flow direction) on tool rake face have better performance than other texture patterns. In this present study, the effect of different lateral micro textures on cutting force, cutting temperature and chip formation were analyzed via an advanced finite element analysis code in rectangular groove cutting processes. Three cutting tools with different lateral micro textures on tool rake face, one is parallel textured (MT1) and two are non-parallel textured (MT2, MT3), were employed in this study. The results indicate that lateral textured tools have significant advantages in terms of controlling chip curl, reducing cutting forces and decreasing cutting temperature. Synthetically, asymmetrical lateral textured tool MT2 show best performance in chip breakability control, decreasing cutting forces, and lower mean cutting temperature along the main cutting edge.

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39

Yoshimaru, Masafumi, Yasuhiro Fujita, Tetsufumi Ito, Masahide Kouya, and Hiroshi Suzuki. "Development of Multi-Axis Cutting Method Using Non-Rotational Tool with Ultrasonic Vibration." International Journal of Automation Technology 2, no. 2 (March 5, 2008): 105–10. http://dx.doi.org/10.20965/ijat.2008.p0105.

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In recent years, rotary tools such as ball and flat end mills are widely used to produce dies and parts. Machining using rotary tools shortens cutting time, raising efficiency and discharging cutting chips cleanly, but leaves the machined face rough due to arc-shaped rotation marks. The radius of rotation for the location of the cutting edge from the tool's center axis is non-consistent, varying tool edge cutting speed and direction, making it difficult to leave surface roughness uniform. Removing unfinished areas and reducing final machined face surface roughness to the submicron level thus requires secondary finishing, which conventionally relies on hand polishing by a skilled worker. We developed extremely small cut-in machining using a non-rotational tool to establish final die machine finishing. We discuss machining tests with ultrasonic vibration added to machine prehardened steel, used mainly as a die material, to a mirror finish using a nonrotational diamond tool, and evaluate its usefulness.

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40

Ozimina, Dariusz, Monika Madej, Joanna Kowalczyk, Ewa Ozimina, and Stanislaw Plaza. "Tool wear in dry turning and wet turning with non-toxic cutting fluid." Industrial Lubrication and Tribology 70, no. 9 (November 19, 2018): 1649–56. http://dx.doi.org/10.1108/ilt-02-2018-0080.

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PurposeThis study aims to determine the properties of a new non-toxic cutting fluid and compared with cutting fluid based on mineral oil.Design/methodology/approachThe tool wear was measured under dry and wet cutting conditions. The non-toxic cutting fluid was compared with cutting fluid based on mineral oil. The experiments were carried out using CTX 310 ECO numerical control lathe. The wear of the cutting tools was measured by means of stereo zoom microscopy (SX80), while the elements were identified through scanning electron microscopy (JSM 7100F). The workpiece surface texture was studied using a Talysurf CCI Lite non-contact 3D profiler. The contact wetting angle was established with a KSV CAM 100 tester.FindingsThe non-toxic cutting fluid has reached comparable coefficient of friction with a coolant containing mineral oil. The use of the non-toxic cutting fluid with low foaming tendency resulted in lower wear.Practical implicationsMachining processes require that cutting fluids be applied to reduce the tool wear and improve the quality of the workpiece surface. Cutting fluids serve numerous purposes such as they act as coolants and lubricants, remove chips and temporarily prevent corrosion of the product.Originality/valueThe investigations discussed in this paper have contributed to the development of non-toxic and environmentally friendly manufacturing because of the use of cutting fluid containing zinc aspartate and its comparison with commonly used cutting fluid.

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41

Wang, Bao Min, Wei Cheng, Ying Kang Zou, and Peng Li. "Study on Cutting Less-Teeth Gear with the Slotting Tool." Advanced Materials Research 314-316 (August 2011): 497–500. http://dx.doi.org/10.4028/www.scientific.net/amr.314-316.497.

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In this paper, firstly, the common equation of involute gear profile was derived with the slotting tool, based on the principle of Envelope Method & Coordinate Transform. Secondly, different equqtions of the involute and transition curve were solved with different gear profiles of slotting tool through some mathmatical substitution. Finally, the model of gear profile equation was bulit with the software Pro/E. After verification, it proved that all derived equations, which can be used to establish the accurate 3D model of gear, are correct.

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42

Zhang, Hai Jun, and Ming Zhou. "Tool Wear in Diamond Cutting Sinusoidal Microstructured Surfaces." Key Engineering Materials 431-432 (March 2010): 94–97. http://dx.doi.org/10.4028/www.scientific.net/kem.431-432.94.

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Tool wear in diamond cutting sinusoidal mircostructured surfaces may be quite different from that in conventional diamond turning as the sharp point tip tool is used and the depth of cut changes cyclically along the profile of the cutting surfaces. In present paper, the diamond tool geometry requirements for cutting sinusoidal microstructured surfaces were analyzed. A series of controlled cutting tests of LY12 were executed on a 2-aixs bench type ultra-precision turning machine which equipped a fast tool servo (FTS). Tool wear patterns were investigated with varied feed speed in diamond cutting sinusoidal microstructured surfaces. The scanning electron microscope (SEM) examination results of tool wear showed that the visible wear was occurred after a short cutting distance. The gradual wear around tool tip and along cutting edges was predominant wear pattern with a low feed speed. The catastrophic fracture wear at tool tip was happened with a high feed speed and the wear of sharp point tip of tool was more serious than that of cutting edges of tool.

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43

Sugihara, Tatsuya, Shota Takemura, and Toshiyuki Enomoto. "Improving Tool Wear Resistance in Inconel 718 Cutting by Considering Surface Microstructures of CBN Cutting Tool." Advanced Materials Research 1136 (January 2016): 561–66. http://dx.doi.org/10.4028/www.scientific.net/amr.1136.561.

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Nickel-based superalloys such as Inconel 718 are known as one of the most difficult-to-cut materials due to their mechanical and chemical properties and the tool life is extremely short. Recently, Cubic-Boron-Nitride (CBN) has received a considerable attention as a material for cutting tools and has been considered to be a major candidate for high performance cutting of Inconel 718. However, the detailed wear behavior of CBN tools in cutting of Inconel 718 is not sufficiently understood yet, and the performances of CBN tools are still insufficient in practical use. To overcome this problem, we first conducted orthogonal cutting experiments on Inconel 718 at low (20 m/min) and high (100 m/min) cutting speeds employing CBN cutting tools to clarify the detailed wear mechanisms. Moreover, relationship between surface microstructures of the cutting tool and wear resistance was investigated. As a result, it was found that a rake face with micro grooves significantly suppressed the crater wear at low cutting speed, although polished surface rake face reduced the initial crater wear by approximately 40 % compared to the non-polished tool in high speed cutting of Inconel 718.

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44

Zhang, Guo Qing, and Suet To. "A Novel Tool Wear Measurement Method in Ultra-Precision Raster Milling." Key Engineering Materials 679 (February 2016): 123–27. http://dx.doi.org/10.4028/www.scientific.net/kem.679.123.

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Tool wear measurement has drawn a significant of attention in the past decades. However, no research has been found on the investigation of tool wear measurement in ultra-precision raster milling (UPRM) process since it is a relative complex cutting process. In the present study, tool wear characteristics were identified by using cutting chip morphologies and a groove cutting. Tool wear investigation using cutting chips is effective because diamond tool wear characteristics can be directly imprinted on the cutting chip surface. Through the inspection of chip surfaces, the profile and location of the tool fracture can be identified. Also, through the groove cutting, the cutting edge retreat due to the tool flank wear can be identified. In this research, a mathematical model was established to calculate the tool retreat. The experimental result shows that the proposed tool wear investigation method is an effective method.

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45

Li, Anhai, Jun Zhao, and Guanming Hou. "Effect of cutting speed on chip formation and wear mechanisms of coated carbide tools when ultra-high-speed face milling titanium alloy Ti-6Al-4V." Advances in Mechanical Engineering 9, no. 7 (July 2017): 168781401771370. http://dx.doi.org/10.1177/1687814017713704.

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Chip morphology and its formation mechanisms, cutting force, cutting power, specific cutting energy, tool wear, and tool wear mechanisms at different cutting speeds of 100–3000 m/min during dry face milling of Ti-6Al-4V alloy using physical vapor deposition-(Ti,Al)N-TiN-coated cemented carbide tools were investigated. The cutting speed was linked to the chip formation process and tool failure mechanisms of the coated cemented cutting tools. Results revealed that the machined chips exhibited clear saw-tooth profile and were almost segmented at high cutting speeds, and apparent degree of saw-tooth chip morphology occurred as cutting speed increased. Abrasion in the flank face, the adhered chips on the wear surface, and even melt chips were the most typical wear forms. Complex and synergistic interactions among abrasive wear, coating delamination, adhesive wear, oxidation wear, and thermal mechanical–mechanical impacts were the main wear or failure mechanisms. As the cutting speed was very high (>2000 m/min), discontinuous or fragment chips and even melt chips were produced, but few chips can be collected because the chips easily burned under the extremely high cutting temperature. Large area flaking, extreme abrasion, and serious adhesion dominated the wear patterns, and the tool wear mechanisms were the interaction of thermal wear and mechanical wear or failure under the ultra-high frequency and strong impact thermo-mechanical loads.

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46

Tuyen, Bui Ngoc, and Nguyen Chi Cong. "The Influence of Part Geometry on Changes of the Dynamic Geometric Parameters of Cutting Tools and Cutting Conditions when Contour Turning on CNC Lathes." Applied Mechanics and Materials 889 (March 2019): 540–46. http://dx.doi.org/10.4028/www.scientific.net/amm.889.540.

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Contour turning is a specific process of the machining on CNC lathes. In the finishing operation, to create the part profile, the turning tool must be moved in a trajectory of a complex flat curve (a toolpath) based on the part profile . The variation of feedrate vector on the toolpath according to the part profile in the machining process will results in changing dynamic geometric parameters of the cutting tool, which affects cutting conditions and machined part quality. This article presents the results of theoretical studies on the influence of part geometry on rake angle, clearance angle, approach angle and end cutting-edge angle of the turning tool. Based on the theoretical development, the authors also set up mathematical expressions that allow to define gouge-free cutting condition and the limit of feedtate for contour turning. An empirical model to define the influence of part geometry on the roughness of the part when countour turning on CNC lathe is also presented in this report.

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47

Chen, Ji Ping, and Rui Jun Yang. "Profile Design of the Helical Groove Milling Tool." Advanced Materials Research 706-708 (June 2013): 1496–99. http://dx.doi.org/10.4028/www.scientific.net/amr.706-708.1496.

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In the process of milling special helicoid , there is a cusp point between its profile curve and linear esicoaginal junction . Ordinary milling cutter can't processing .If milling tool profiles are calculated and designed by smooth connection, the findings of milling tool profiles will appear profiles jagged or profiles detached phenomena. For separation of milling cutter blade shape, in order to prevent point was cut off, it can be treated with the method of open groove, but the two point easy to wear and affect the durability of the cutting tool. Solving method of transitional profiles of detached section is given.

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48

Osmer, Jen, A. Meier, R. Gläbe, O. Riemer, and E. Brinksmeier. "Ultra Precision Machining of Non-Ferrous Metals and Nitrocarburized Tool Steel." Key Engineering Materials 447-448 (September 2010): 46–50. http://dx.doi.org/10.4028/www.scientific.net/kem.447-448.46.

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This paper presents results for the machining of materials typically applied in ultra precision machining in comparison to a nitrocarburized tool steel. Analyzing and evaluating the machining results regarding surface integrity lead to recommendations for the ultra precision machining of this new mold material. The influence of feed, depth of cut and cutting speed on surface quality, resulting cutting forces and tool wear have been investigated. The results show that the decisive factor for the ultra precision machining of nitrocarburized tool steel are the significantly higher cutting forces. In some cases the high cutting forces lead to vibrations during the turning process deteriorating the surface integrity. Therefore, tool nose radius and depth of cut have to be reduced to minimize the cutting forces and avoid the vibrations.

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49

Banerjee, A., and E. V. Bordatchev. "Effect of circular tool path on cutting force profile in micro-end-milling." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 226, no. 6 (September 29, 2011): 1589–600. http://dx.doi.org/10.1177/0954406211423575.

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Micro-end-milling requires high spindle rotational speed to achieve effective material removal. This results in the requirement of tool stoppage or slowdown during a micro-end-milling operation, a deterrent to productivity and to part acceptability. A circular tool path geometry can avoid discontinuities in the tool movements leading to a more consistent and smooth material removal. However, optimal process planning for such a tool path will require detailed understanding of the chip-formation mechanism in circular end-milling. The cut geometry during end-milling along a circular tool path is often approximated as that of a linear tool path. Although this assumption works well for circular tool paths with higher tool path radius, this is not the case for lower tool path radius often used in micro-milling. In this study, the effect of circular tool path on the cutting force for varying tool path rotation angle, tool path radius, and feed rate is experimentally investigated. Systematic signal processing was applied to analyse the measured cutting force signal along linear and several circular tool paths. Qualitative as well as quantitative differences were observed in the cutting force profiles obtained using different tool path radii, tool path orientations, and feed rates. This implies the need for an improved chip thickness formulation dedicated to micro-end-milling with circular tool path rather than approximating it with formulations derived for linear tool path.

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50

Marques, Maria José, J. C. Outeiro, A. Morão Dias, Rachid M'Saoubi, and Hariharan Chandrasekaran. "Surface Integrity of H13 ESR Mould Steel Milled by Carbide and CBN Tools." Materials Science Forum 514-516 (May 2006): 564–68. http://dx.doi.org/10.4028/www.scientific.net/msf.514-516.564.

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The quality of a mechanical component such as its geometrical accuracy stability and fatigue life are significantly affected by the surface integrity generated by machining process. Residual stresses are a major part of the mechanical state of a machined layer and they can be beneficial or detrimental depending of their nature and magnitude. This study concerns phase analysis and residual stress profile characterization by X-ray diffraction (XRD) technique and microhardness profile of AISI H13 ESR mould steel, milled using carbide and CBN tools. Analysis of the cross-section of the AISI H13 ESR samples, milled using both tools, reveal a martensitic microstructure, with a very thin layer heavily deformed due to the machining process. However, no phase transformation was detected by XRD. Concerning the residual stresses, the results show that they are predominantly compressive at the samples surface. However, depending of the cutting tools, the in-depth residual stresses profiles present different evolutions. This difference in the in-depth residual stresses profiles between the two kind of cutting tools is attributed to the different cutting tool parameters, including the tool geometry.

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