Cutting Tool Wear Prediction with Taylor’s Equation in Aspen Wood Longitudinal Milling | Chapter 6 | Science and Technology: Recent Updates and Future Prospects Vol. 11

 

Taylor's Equation has proven utility for determining the lifetime of cutting tools in the machining of metal. Whereas, Taylor's Equation is not widespread for the prediction of wear of wood machining tools due to the lack of appropriate coefficients of the Equation. A computer numerical control machine was used for conventional longitudinal milling of aspen (Populus tremula L.) wood with cutter knives of high-alloy tool steel X150CrMo12 according to European standard EN 10027-1:2016 on the cutter head. Changes in the surface roughness characterized the wear phases of the cutting tool at two different values of cutting velocity were obtained depending on the length of the cutting trajectory as it is more appropriate for forecasting tool wear compared to the time of cutting because the time depends on the feed speed. Research showed that the achievable length of cutting trajectory until the critical wear phase increases approximately two times from 45000 to 96000 m per tooth when cutting velocity is increased from 20 to 40 m s-1. The equation to predict the achievable length of cutting trajectory was obtained depending on the cutting velocity–the main factor affecting tools wear the most. It was noted that also other parameters of the cutting regime mostly the angular parameters of the cutter, feed speed, chip thickness and cutting depth are affecting the tool wear and must be included in the Equation in future research.

 

 

Author(s) Details

 

Andis Abele
Institute of Civil Engineering and Woodworking, Latvia University of Life Sciences and Technologies, Jelgava, Latvia.

 

Please see the link:- https://doi.org/10.9734/bpi/strufp/v11/1798

Experimental Scheme to Monitor Eigenvalues of Vibration Signals in Cutting Tool Milling | Chapter 6 | Current Topics and Emerging Issues in Materials Sciences Vol. 2

 In order to better resolve the problem of veracity of tool wear status forecasting, the extraction of feature principles of tool wear facts from the sensors is the basis for resolving the problem. This chapter designs an exploratory scheme to monitor the form wear state by extracting the quivering signal of tool wear. Milling tool wear state acknowledgment plays an important function in controlling the character of milled parts and lowering machine tool downtime. However, the traits of milling process limit the veracity and stability of form condition monitoring employing quivering signals. A T-type cutting finish, a vibration sensor, an speaker, a data acquisition badge, and a computer compensate the data addition and signal processing fittings. The vibration signal is statistically analysed in the time rule, and it is determined that the difference of the vibration signal made by X-axis wear is positively belonging to the level of tool wear. Moreover, the quivering signal is converted from period domain to commonness domain by Fourier transform, and the characteristic commonness bands of vibration signal are 2~4 kHz and 7~9 kHz deficiency domain.  The DB4 wavelet of Daubechies succession wavelets is used as the wavelet packet base, and the DB4 wavelet bundle base has features to a degree smoothness in addition to matching wavelet fast algorithms Wavelet small decomposition technology is used to extract the eigenvalues of shaking signals. In addition, the characteristics at an unspecified future time domain, repetitiveness domain and frequency rule are also conferred.  It is further judged that the strength percentage of 2.5~3.75 kHz and 7.5~8.25 kHz is carefully related to tool wear, so the strength percentage of two together characteristic frequency bands is picked as the characteristic value of tool wear listening.

Author(s) Details:

Liqiang Wang,

Electronic Engineering School, Tianjin University of Technology and Education, Tianjin, China.

Xiao Li,

Electronic Engineering School, Tianjin University of Technology and Education, Tianjin, China.

Bo Shi,

Electronic Engineering School, Tianjin University of Technology and Education, Tianjin, China.

Munyaradzi Munochiveyi,

Electrical and Electronics Engineering Department, University of Zimbabwe, Harare, Zimbabwe.

Please see the link here: https://stm.bookpi.org/CTEIMS-V2/article/view/11313

Determination of Finite Element Analysis of Chip Formation using ALE Method | Chapter 10 | Recent Trends in Chemical and Material Sciences Vol.7

 Many recent FEM investigations on the formulation of plain isotropic metal plates have been undertaken. In terms of structural safety and system stability, stress analysis is critical. For designing and manufacturing high-quality items, stress and distortion estimate is particularly useful. Residual stress and plastic strain dictate a structure's fatigue life in most cases, but they also play a role in design and material selection. A crack forms as the size of the load increases, reducing the work load and residual stress, and thereby reducing metal damage. The manufacturing process is an important factor in the process and the formation of any system. Complex things like hot development, material characteristics, and other predictions based on plastic strain and residual stress transition are involved in machining operations. The complexity of the finite element research is influenced by the decrease of residual stress. The focus of this research is on manufacturing techniques with lower residual stress and strain. For the simulation of metal removal processes, an arbitrary LagrangianEulerian (ALE) formulation has been devised in this article. The results show that by employing the ALE method in machining, we may minimise the strain on the work piece and hence increase its life type. Cutting tool wear and efficiency are also investigated because they are an important machine component in fabrication technology. The ABAQUS platform was used to solve the machining operation.

Author(s) Details:

Jayaprakash Venugopal,
School of Mechanical, Sathyabama Institute of Science and Technology, Chennai, India.


Anish Mariadhas,
School of Mechanical, Sathyabama Institute of Science and Technology, Chennai, India.

Please see the link here: https://stm.bookpi.org/RTCAMS-V7/article/view/6103

Studies on Optimization of Tool Wear in Hard Turning of EN 24 Steel Using DoE and Verification through ANOVA and RSM | Chapter 15 | Novel Perspectives of Engineering Research Vol. 4

 This research shows how Multicoated hard metal inserts with sculptured rake face geometry may anticipate tool wear in hard turning of 817M40 (EN 24) steel material with 48 HRC on a conventional lathe. Tool wear becomes a significant factor in the surface quality of produced items with hard turning. In order to predict tool wear, an effort is made to combine cutting force, cutting temperature, and tool vibration (displacement) with cutting velocity, feed, and depth of cut. In this study, Taguchi L18 orthogonal array (mixed design) optimization was utilised to optimise various cutting parameters such as cutting velocity, feed, and depth of cut using Minitab software. Furthermore, the outcomes of the Design of Experiment are compared to the ANOVA Response Surface approach (RSM). Response surface methodology (RSM) and Analysis of Variance (ANOVA) yield results that are remarkably similar to those obtained by Design of Experiment (DoE).

Author(S) Details

G. Ragul
Department of Mechanical Engineering, Budge Budge Institute of Technology, Kolkata, India.

Pallab Roy
Department of Mechanical Engineering, Budge Budge Institute of Technology, Kolkata, India.

Arjit Ganguly
Mechatronics, Warsaw University of Technology, Poland.

Sandip Ghosh
Department of Mechanical Engineering, JIS College of Engineering, Kalyani, India.

S. Sankar
Department of Mechanical Engineering, Nehru College of Engineering & Research Centre, Kerala, India.

Abhijit Roy
Department of Mechanical Engineering, Budge Budge Institute of Technology, Kolkata, India.

View Book:- https://stm.bookpi.org/NPER-V4/article/view/5180

Investigating the Effect of Feeding Angle on the Performance of a Two-way Application of Cutting Fluids | Chapter 1 | Innovations in Science and Technology Vol. 1

 The performance of a two-way cutting fluid application was investigated to examine how a change in the angle of cutting fluid (CF) feeding impacts it. The inspiration for this study stemmed from the fact that little or no research has been done on a two-way CF application, as well as the findings of our previous study. The studies were carried out on an XL400 centre lathe machine. The cutting tool was a rectangular cemented carbide tool insert, and the workpiece was medium carbon steel. The surface quality of the machined workpiece, the rate of tool wear, and the temperature of the cutting zone were all studied under various feeding angles. The experiments were carried out under the following machining conditions: Cut depth (t) =1.5 mm, rotational speed (V) = 180 rpm, and feed rate (f) = 0.75 mm/rev In terms of surface quality, the two-way cutting fluid application was most effective when the feeding angle was 150o. i.e. at this angle, the lowest surface roughness value was attained, which was 5.77 m compared to 9.67 m for one-way CF application. In other words, the roughness of the surface was reduced by 40.3 percent. The tool wear and temperature at the cutting zone for the two-way application were 0.11 mm and 25.60oc, respectively, compared to 0.15 mm and 30.48oc for the one-way application. At a feeding angle of 60o, the lowest tool wear (maximum tool life) and temperature were achieved. For the two-way application, the tool wear and temperature were 0.11 mm and 24.54oC, respectively, compared to 0.15 mm and 30.48oC for the one-way application. Self-excited vibrations of the machine tool may be to blame for some of the aberrant values obtained for the two-way application. At this angle, the surface roughness value was 6.79 m, which was the next lowest value in the entire experiment. As a result, the most effective angles for supplying CF to the cutting zone via two-way application were 60o and 150o, respectively. As a result of the findings, it can be concluded that the angle at which CF is fed to the cutting zone has a bigger impact on its effectiveness.

Author(S) Details

S. O. Yakubu
Department of Mechanical Engineering, Faculty of Engineering, Nigerian Defence Academy, P.M.B 2109, Kaduna, Nigeria.

S. Y. Aku
Department of Mechanical Engineering, Faculty of Engineering, Nigerian Defence Academy, P.M.B 2109, Kaduna, Nigeria.

M. J. Apochi
Department of Mechanical Engineering, Faculty of Engineering, Nigerian Defence Academy, P.M.B 2109, Kaduna, Nigeria.

View Book:- https://stm.bookpi.org/IST-V1/article/view/5073