Cutting Zone

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Kornel F. Ehmann - One of the best experts on this subject based on the ideXlab platform.

  • experimental investigation of hard turning mechanisms by pcbn tooling embedded micro thin film thermocouples
    Journal of Manufacturing Science and Engineering-transactions of The Asme, 2013
    Co-Authors: Kornel F. Ehmann
    Abstract:

    Temperature-distribution measurements in Cutting tools during the machining process are extremely difficult and remain an unresolved problem. In this paper, Cutting temperature distributions were measured by thin film thermocouples (TFTCs) embedded into polycrystalline cubic boron nitride (PCBN) Cutting inserts in the immediate vicinity of the tool-chip interface. The embedded TFTC array provides temperature measurements with a degree of spatial resolution (100 μm) and dynamic response (150 ns) that is not possible with currently employed methods due to the micro-scale junction size of the TFTCs. Using these measurements during hard turning, steady-state, dynamic, as well as chip morphology and formation process analyses were performed based on the Cutting temperature and Cutting force variations in the Cutting Zone. It has been shown that the temperature changes in the Cutting Zone depend on the shearing band location in the chip and the thermal transfer rate from the heat generation Zone to the Cutting tool. Furthermore, it became evident that the material flow stress and the shearing bands greatly affect not only the chip formation morphology but also the Cutting temperature field distributions in the Cutting Zone of the Cutting insert.

  • A thermo-mechanical model of dry orthogonal Cutting and its experimental validation through embedded micro-scale thin film thermocouple arrays in PCBN tooling
    International Journal of Machine Tools and Manufacture, 2013
    Co-Authors: Kornel F. Ehmann
    Abstract:

    Abstract Cutting temperature and its distribution in the Cutting Zone are a critical factor that significantly affects tool life and degrades part accuracy during metal removal operations. However, issues surrounding their modeling and experimental validation in the immediate Cutting Zone still remain an unresolved issue. A major impediment is the unavailability of adequate temperature measurement methods with sufficient temporal and spatial resolution to measure actual temperatures and validate predictive models. In this paper, a model for the dry orthogonal Cutting process with thermo-mechanical coupling effects, i.e., interactions between the stress state, strain rates and the temperature softening of material in the plastic deformation Zone, is proposed to predict Cutting temperature distribution in the Cutting Zone. The feasibility and prediction accuracy of the model is verified by experimental measurements through Thin Film Thermocouple (TFTC) arrays embedded at the immediate vicinity of the Cutting Zone into Polycrystalline Cubic Boron Nitride (PCBN) tooling. The experimental verification is performed under hard turning conditions. It has been shown that the predictions of the proposed model are in very close agreement with the experimentally measured results including the Cutting forces, chip thickness and Cutting temperature distributions on the rake and flank faces in the Cutting Zone. Furthermore, the modeling results have also provided an essential understanding on the stress distributions at the tool/chip and work/tool interfaces as well as of the nature of the chip flow velocity along the rake face of the Cutting tool.

Wei Peng - One of the best experts on this subject based on the ideXlab platform.

  • Effects of magnetic field distributions on wire sawing performance
    Precision Engineering, 2017
    Co-Authors: Zhang Wei, Qiu Tengwei, Chunyan Yao, Wei Peng
    Abstract:

    Abstract To transport more abrasive grains into the Cutting Zone, the method of magnetic-induction free-abrasive wire sawing is proposed. A uniform magnetic field is used to magnetize a steel wire and forms a high gradient magnetic field around the wire. The magnetic abrasive grains are adsorbed on the magnetized wire and are transported into the Cutting Zone, which improves the wire sawing performance. The adsorption of the magnetic abrasive grains is observed using an experimental setup along the wire cross-sectional direction. The results suggest that magnetic abrasive grains are increasingly adsorbed in the paramagnetic region of the wire with increasing magnetic field intensity. Single-wire sawing experiments are conducted on a WXD170 reciprocating wire sawing machine at variable magnetic field intensity and distribution. The results suggest that the change in magnetic field intensity strongly affects the Cutting efficiency, kerf loss, and surface roughness. The performance of the magnetic-induction free-abrasive wire sawing under different magnetic field intensities and distributions are compared. The wire sawing performance improves when the uniform magnetic field is evenly distributed in the Cutting Zone and at the top of Cutting Zone.

Łukasz Ślusarczyk - One of the best experts on this subject based on the ideXlab platform.

Emilia Franczyk - One of the best experts on this subject based on the ideXlab platform.

Marian Bartoszuk - One of the best experts on this subject based on the ideXlab platform.

  • Temperature and Heat Partition Testing in the Cutting Zone for Turning AISI 321 Steel
    Strojniški vestnik – Journal of Mechanical Engineering, 2020
    Co-Authors: Marian Bartoszuk
    Abstract:

    This article shows selected results of experimental tests and the results of analytical and numerical modelling of the thermal characteristics of the Cutting process. The tests were conducted for the case of the dry turning of austenitic steel AISI 321 with Cutting tools with a flat rake face. The research aimed to determine the actual division of thermal fluxes in the Zone of contact between the chip and the rake face. As a result of such work, a formula for a new heat partition coefficient and a formula for calculating the average contact temperature were developed. The results showed that the formulas developed can be a useful tool to estimate heat distribution in the Cutting Zone quickly.

  • THERMOVISION MEASUREMENTS OF THE TEMPERATURE IN THE Cutting Zone FOR TURNING AISI 321 STEEL
    Technical Sciences, 2020
    Co-Authors: Marian Bartoszuk
    Abstract:

    The article presents the methodology of conducting research on temperature distribution in the Cutting Zone for orthogonal turning without the use of a cooling liquid. AISI 321 austenitic steel was chosen as the workpiece material to be tested, while TNMA160408 carbide inserts, with a flat rake face made of H10F carbide, were chosen as the Cutting edges. The research used infrared imaging, which still poses many research problems. The author's own method of calibration of the measurement chain is also presented. In addition, the most common causes of inaccuracies in thermovision measurements of Cutting temperatures are discussed. The obtained temperature distribution maps were related to the average contact temperature determined by the method of natural thermocouple – chips/rake face.

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