Skip to main content
SpringerLink
Log in

Analysis of cutting forces and chip formation in milling of marble

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In this study, high-speed milling of marble was conducted with a coated carbide ball nose end mill. Single-factor cutting tests were designed to investigate the effect of milling parameters on cutting forces and marble chips. It was found that the cutting forces in three directions increased with the increasing feed rate and decreased with the increasing cutting speed. The morphology and particle size of marble chips were analyzed. The transgranular fracture was found to be the predominant failure mode in the milling process. In addition, it was found that the particle size of marble chips increased with the increasing feed rate and decreased with the increasing cutting speed. There was an obvious positive correlation between the cutting forces and chip formation. The experimental results were significant for a better understanding of the material removal mechanism and selection of cutting parameters in the machining of rock materials.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

References

  1. Nishimatsu Y (1972) The mechanics of rock cutting. Int J Rock Mech Min Sci Geomech Abstr 9(2):261–270

    Google Scholar 

  2. Hood M, Alehossein H (2000) A development in rock cutting technology. Int J Rock Mech Min 37(1–2):297–305

    Google Scholar 

  3. Ozfirat PM (2012) An integer programming approach for the three-dimensional cutting planning problem of marble processing industry. Int J Adv Manuf Technol 59(9–12):1057–1064

    Google Scholar 

  4. Menezes PL, Lovell MR, Avdeev IV (2014) Studies on the formation of discontinuous chips during rock cutting using an explicit finite element model. Int J Adv Manuf Technol 70(1–4):635–648

    Google Scholar 

  5. Menezes PL (2017) Influence of rock mechanical properties and rake angle on the formation of rock fragments during cutting operation. Int J Adv Manuf Technol 90(1–4):127–139

    Google Scholar 

  6. Liu W, Zhu X, Jing J (2018) The analysis of ductile-brittle failure mode transition in rock cutting. J Pet Sci Eng 163:311–319

    Google Scholar 

  7. Li X, Zhang Q, Li J, Zhao J (2018) A numerical study of rock scratch tests using the particle-based numerical manifold method. Tunn Undergr Spec Technol 78:106–114

    Google Scholar 

  8. Huo J, Wang W, Sun W, Ling J, Dong J (2017) The multi-stage rock fragmentation load prediction model of tunnel boring machine cutter group based on dense core theory. Int J Adv Manuf Technol 90(1–4):277–289

    Google Scholar 

  9. Rostamsowlat I (2017) Effect of cutter and rock properties on the frictional contact in rock cutting with blunt tools. Curtin University, Australia, PhD’s thesis

    Google Scholar 

  10. Cheng Z, Sheng M, Li G, Huang Z, Shi H, Dai X, Guo Z (2019) Cracks imaging in linear cutting tests with a PDC cutter: characteristics and development sequence of cracks in the rock. J Pet Sci Eng 179:1151–1158

    Google Scholar 

  11. Che D, Ehmann K (2014) Experimental study of force responses in polycrystalline diamond face turning of rock. Int J Rock Mech Min 72:80–91

    Google Scholar 

  12. Yang D, Li J, Wang L, Gao K, Tang Y, Wang Y (2015) Experimental and theoretical design for decreasing wear in conical picks in rotation-drilling cutting process. Int J Adv Manuf Technol 77(9–12):1571–1579

    Google Scholar 

  13. Hamade RF, Pusavec F, Manthri SP, Dillon OW Jr, Jawahir IS (2012) A methodology for the optimization of PCD compact core drilling in basalt rock. Int J Adv Manuf Technol 61(1–4):369–377

    Google Scholar 

  14. Atici U, Ersoy A (2009) Correlation of specific energy of cutting saws and drilling bits with rock brittleness and destruction energy. J Mater Process Technol 209(5):2602–2612

    Google Scholar 

  15. Brook B (2002) Principles of diamond tool technology for sawing rock. Int J Rock Mech Min 39(1):41–58

    Google Scholar 

  16. Aydin G, Karakurt I, Hamzacebi C (2014) Artificial neural network and regression models for performance prediction of abrasive waterjet in rock cutting. Int J Adv Manuf Technol 75(9–12):1321–1330

    Google Scholar 

  17. Liu S, Ji H, Han D, Guo C (2018) Experimental investigation and application on the cutting performance of cutting head for rock cutting assisted with multi-water jets. Int J Adv Manuf Technol 94(5–8):2715–2728

    Google Scholar 

  18. Turchetta S, Polini W (2011) Cutting force in stone lapping. Int J Adv Manuf Technol 57(5–8):533–539

    Google Scholar 

  19. Saidi MN, Songmene V, Kouam J, Bahloul A (2015) Experimental investigation on fine particle emission during granite polishing process. Int J Adv Manuf Technol 81(9–12):2109–2121

    Google Scholar 

  20. Saidi MN, Songmene V, Kouam J, Bahloul A (2019) Study of surface quality and dust particles emission and dispersion during dry polishing of granite. Int J Adv Manuf Technol 104(9–12):4675–4684

    Google Scholar 

  21. Appl FC, Wilson CC, Lakshman I (2017) Measurement of forces, temperatures and wear of PDC cutters in rock cutting. Wear 169(1):9–24

    Google Scholar 

  22. Turchetta S (2009) Cutting force on a diamond grit in stone machining. Int J Adv Manuf Technol 44(9–10):854–861

    Google Scholar 

  23. Turchetta S (2012) Cutting force and diamond tool wear in stone machining. Int J Adv Manuf Technol 61(5–8):441–448

    Google Scholar 

  24. Gelfusa G, Turchetta S (2014) Cutting force and tool wear of single diamond-coated bead. Int J Adv Manuf Technol 72(5–8):1063–1072

    Google Scholar 

  25. Che D, Zhang W, Ehmann K (2017) Chip formation and force responses in linear rock cutting: An experimental study. J Manuf Sci Eng Trans ASME 139(1):011011

    Google Scholar 

  26. Che D, Zhu WL, Ehmann KF (2016) Chipping and crushing mechanisms in orthogonal rock cutting. Int J Mech Sci 119:224–236

    Google Scholar 

  27. Choi SW, Chang SH, Park YT, Lee GP, Bae GJ (2013) A experimental study on the loads and temperature acting on the shaft of a disc cutter during linear rock cutting test. J Kr Tunn Undergr Sp Assoc 15(3):237–251

    Google Scholar 

  28. Shao W, Li X, Sun Y, Tang J (2018) An experimental study of temperature at the tip of point-attack pick during rock cutting process. Int J Rock Mech Min 107:39–47

    Google Scholar 

  29. Dagrain F (2001) Influence of the cutter geometry in rock cutting: an experimental approach. University of Minnesota, Minneapolis

    Google Scholar 

  30. Doshvarpassand S, Richard T, Mostofi M (2017) Effect of groove geometry and cutting edge in rock cutting. J Pet Sci Eng 151:1–12

    Google Scholar 

  31. Rostamsowlat I (2018) Effect of cutting tool properties and depth of cut in rock cutting: an experimental study. Rock Mech Rock Eng 51(6):1715–1728

    Google Scholar 

  32. Rostamsowlat I, Richard T, Evans B (2018) An experimental study of the effect of back rake angle in rock cutting. Int J Rock Mech Min 107:224–232

    Google Scholar 

  33. Yadav S, Saldana C, Murthy TG (2018) Experimental investigations on deformation of soft rock during cutting. Int J Rock Mech Min 105:123–132

    Google Scholar 

  34. Innaurato N, Oreste P (2011) Theoretical study on the TBM tool-rock interaction. Geotech Geol Eng 29(3):297–305

    Google Scholar 

  35. Yurdakul M, Akdas H (2012) Prediction of specific cutting energy for large diameter circular saws during natural stone cutting. Int J Rock Mech Min 53:38–44

    Google Scholar 

  36. Yasar S, Yilmaz AO (2017) Rock cutting tests with a simple-shaped chisel pick to provide some useful data. Int J Rock Mech Min 50(12):3261–3269

    MathSciNet  Google Scholar 

  37. Tiryaki B, Dikmen AC (2006) Effects of rock properties on specific cutting energy in linear cutting of sandstones by picks. Rock Mech Rock Eng 39(2):89–120

    Google Scholar 

  38. Sarıışık G, Özkan E (2018) Effects of natural rock properties on cutting forces, specific energy and specific cutting energy by four-axis machine. Arab J Geosci 11(5):84

    Google Scholar 

  39. Qi G, Ying WZ, Hao M, Qiao C (2016) Numerical and experimental research on the rock-breaking process of tunnel boring machine normal disc cutters. J Mech Sci Technol 30(4):1733–1745

    Google Scholar 

  40. He X, Xu C (2016) Specific energy as an index to identify the critical failure mode transition depth in rock cutting. Rock Mech Rock Eng 49(4):1461–1478

    Google Scholar 

  41. Wang X, Su O (2019) Specific energy analysis of rock cutting based on fracture mechanics: a case study using a conical pick on sandstone. J Mech Sci Technol 30(4):1733–1745

    Google Scholar 

  42. Jiang F, Luan X, Wang N, Xu X, Lu X, Wen Q (2018) Research on the dynamic mechanical properties of C-plane sapphire under impact loading. Ceram Int 44(8):9839–9847

    Google Scholar 

  43. Gong FQ, Si XF, Li XB, Wang SY (2019) Dynamic triaxial compression tests on sandstone at high strain rates and low confining pressures with split Hopkinson pressure bar. Int J Rock Mech Min 113:211–219

    Google Scholar 

  44. Yao W, He T, Xia K (2017) Dynamic mechanical behaviors of Fangshan marble. Int J Rock Mech Geotech Eng 9(5):807–817

    Google Scholar 

  45. Zhang QB, Zhao J (2013) Effect of loading rate on fracture toughness and failure micromechanisms in marble. Eng Fract Mech 102:288–309

    Google Scholar 

  46. Zhang QB, Zhao J (2014) Quasi-static and dynamic fracture behaviour of rock materials: phenomena and mechanisms. Int J Fract Mech 189(1):1–32

    Google Scholar 

  47. Luan X, Jiang F, Wang N, Xu X, Lu X, Wen Q (2018) The mechanical response characteristics of sapphire under dynamic and quasi-static indentation loading. Ceram Int 44(13):15208–15218

    Google Scholar 

  48. Wang K, Jiang F, Yan L, Xu X, Wang N, Zha X, Lu X, Wen Q (2019) Study on mechanism of crack propagation of sapphire single crystals of four different orientations under impact load and static load. Ceram Int 45(6):7359–7375

    Google Scholar 

Download references

Funding

This work was supported by the National Natural Science Foundation of China (No. 51705162 and No. U1805251), Natural Science Foundation of Fujian Province (No. 2018J01077), and the Industrial linkage Collaborative Innovation Project of Xiamen City (No. 3502Z20183021).

Author information

Authors and Affiliations

  1. Institute of Manufacturing Engineering, Huaqiao University, Xiamen, 361021, Fujian, China

    Fuzeng Wang, Shuying Liu, Ziyu Guo & Liang Cao

  2. Fujian Engineering Research Center of Intelligent Manufacturing for Brittle Materials, Xiamen, Fujian, 361021, China

    Fuzeng Wang

Authors
  1. Fuzeng Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Shuying Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Ziyu Guo
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Liang Cao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Fuzeng Wang.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wang, F., Liu, S., Guo, Z. et al. Analysis of cutting forces and chip formation in milling of marble. Int J Adv Manuf Technol 108, 2907–2916 (2020). https://doi.org/10.1007/s00170-020-05575-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-020-05575-5

Keywords

Search

Navigation