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A systemic investigation of tool edge geometries and cutting parameters on cutting forces in turning of Inconel 718

  • Xing Dai
  • Kejia ZhuangEmail author
  • Han Ding
ORIGINAL ARTICLE
  • 98 Downloads

Abstract

In metal cutting process, size effects and edge effects have a significant influence on cutting forces and therefore on the machining performance. This paper facilitates those behaviors with different cutting tool geometry, i.e., round edge and chamfered edge, using analytical cutting force prediction models when turning Inconel 718 with round cutting inserts. Analytical methods used for different edge preparation are developed with the consideration of size effects and edge effects. Then, an attempt is made to analyze the cutting investigations of the influence of size effects and edge features. The cutting forces and edge forces are estimated with the modified Johnson–Cook constitute model considering the size effects and edge effects. Rounded edge coefficients and chamfered edge coefficients estimated with different analytical methods are used in calculating edge forces for rounded edged tools and chamfered edged tools, respectively. Simulations with finite element model (FEM) and cutting experiments are used to verify the proposed model. Finally, the detailed influences of size effects, edge geometries, and feed rate on the cutting forces are studied based on the proposed model and FEM simulations.

Keywords

Edged inserts Size effect Analytical model Cutting force 

Abbreviations

R

Radius of round insert

f, fc

Feed rate, feed rate on rake face plane

hjc

Uncut chip thickness on the rake face plane

ϕstϕmidϕex

Separation immersion angles

ϕs, ϕsj

Immersion angle, immersion angle of element j

αn

Normal rake angle

FxjFyjFzj

Force components on element j in cutting in Caretesian coordinate system

FtjFrjFfj

Force components on element j in cutting velocity, tangential and radial direction

ap

Cutting depth

djc

Width of uncut chip zone of element j

Doc

Depth of cut in simulations

λs0λsj

Initial inclination angle, inclination angle of element j

KtcjKrcjKfcj

Cutting coefficients

KtejKrejKfej

Edge coefficients

τsj

Shear flow stress of element j

ηcj

Local chip flow angle of element j

βnj

Friction angle of element j

r

Edge radius

θ

Chamfer angle

l

Chamfer length

θ0

Stagnation point angle

γ, \( \dot{\gamma} \)

Shear strain and shear strain rate

\( {\dot{\gamma}}_0 \)\( {\dot{\gamma}}_m \)

Reference plastic strain rate and maximum strain rate

T, Tr, Tm

Chip instantaneous temperature, room temperature and melting temperature

ϕnj

Normal shear angle of element j

Vjc

Chip flow velocity of element j

fj

Mean friction coefficient

f0, p

Constants of friction coefficient

ρ c μ

Density of the material, specific heat capacity, Taylor-Quinney coefficient

A, B, C, m, n

Coefficients of the Johnson–Cook model

bg

Magnitude of the Burgers vector

M\( \overline{r} \)G

Taylor factor, Nye factor, shear modulus

Notes

Funding information

This work is partially supported by the National Natural Science Foundation of China (51705385), the State Key Laboratory of Digital Manufacturing Equipment and Technology (DMETKF2017019), and the Fundamental Research Funds for the Central Universities (2018-IVB-009).

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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.State Key Laboratory of Digital Manufacturing Equipment and TechnologyHuazhong University of Science and TechnologyWuhanChina
  2. 2.Hubei Digital Manufacturing Key Laboratory, School of Mechanical and Electronic EngineeringWuhan University of TechnologyWuhanChina

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