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Zhenyu Shi - One of the best experts on this subject based on the ideXlab platform.
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evaluation of Specific Cutting Energy considering effects of Cutting tool geometry during micro machining process
The International Journal of Advanced Manufacturing Technology, 2019Co-Authors: Peng Cui, Zhenyu Shi, Ningmin DuanAbstract:Sustainability is a growing interest in basic industry. The ultimate goal for manufacturing industry is environmental releases, and sustainable development. By reducing Energy consumption, economic and environmental performance can be significantly improved for the manufacturing systems. In this paper, the Cutting force and Specific Cutting Energy (SCE) consumption are evaluated based on the calculated material removal volume. Three different Cutting tool geometries, including the C-, D-, and T-shaped turning indexable tools, are examined to investigate how Cutting tool geometry affects the Cutting force and SCE. Experimental research and theoretical modeling analysis have been conducted. Statistical analysis for theoretical and experimental SCE has been conducted to extract the effect of each factor on variation. Results of this research show that the more volume of Cutting tool involved into the workpiece, the smaller the SCE produced. Optimal setting for sustainability target in terms of minimum Cutting Energy being consumed could be obtained through the established model.
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investigation on size effect of Specific Cutting Energy in mechanical micro Cutting
The International Journal of Advanced Manufacturing Technology, 2017Co-Authors: Tao Zhang, Zhanqiang Liu, Zhenyu ShiAbstract:Mechanical micro-Cutting is one of advanced processes to manufacture the miniature parts. The uncut chip thickness is one of the two important parameters in mechanical Cutting. The uncut chip thickness and the Cutting edge radius are at the same length scale, and the Cutting tool extrudes and shears the workpiece with the round Cutting edge during micro-Cutting process. Size effect of Specific Cutting Energy in micro-Cutting is significant in comparison with that in macro Cutting. A slip-field model is proposed in this paper to analyze the deformation process of workpiece material in micro-Cutting. Johnson–Cook constitutive model, which includes shear strain hardening, shear strain rate hardening, shear temperature softening, and plasticity strain gradient (PSG) effects, is applied to the calculation of the shear flow stress at the primary shear zone (PSZ). Predicted Cutting force using the shear flow stress is validated by the micro-orthogonal Cutting experiments. The Specific Cutting Energy is also calculated. It shows that the size effect on Specific Cutting Energy in micro-Cutting is influenced greatly by the shear strain hardening, shear strain rate hardening, shear temperature softening, and relative Cutting length due to the ratio of uncut chip thickness to Cutting edge radius. The plasticity strain gradient has effect on the Specific Cutting Energy when the uncut chip thickness is smaller than 25 μm for micro-orthogonal Cutting AISI 1045 steel.
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Proper selection of Cutting parameters and Cutting tool angle to lower the Specific Cutting Energy during high speed machining of 7050-T7451 aluminum alloy
Journal of Cleaner Production, 2016Co-Authors: Bing Wang, Qinghua Song, Zhanqiang Liu, Yi Wan, Zhenyu ShiAbstract:Cleaner production and sustainability are of vital importance in the field of machining processes where great amount of Energy is consumed. Reducing the Energy consumption during machining process can significantly improve the environmental and economical performance of manufacturing systems. To achieve this, calculation of Energy consumption during the metal Cutting process is required. This paper investigates the Specific Cutting Energy consumption for the serrated chip formation of 7050-T7451 aluminum alloy in high speed machining. The Cutting Energy consumption during serrated chip formation mainly includes such three components as plastic deformation Energy in the primary deformation zone, friction work between the tool-chip interface and kinetic Energy of the flowing chip. The predictive models of these three Energy components are developed for orthogonal Cutting mode, and the influences of Cutting speed, undeformed chip thickness and tool rake angle on the Cutting Energy consumption are revealed. Meanwhile, the theoretical Energy consumptions under different undeformed chip thicknesses are validated with the high speed orthogonal Cutting experiments of 7050-T7451 aluminum alloy. Based on the research results, when high Cutting speeds are applied in order to improve the machining efficiency, large positive rake angle tools and large undeformed chip thicknesses are recommended if the rigidity of the machining system and the machining surface quality can be guaranteed.
Antonio Sanchez J Egea - One of the best experts on this subject based on the ideXlab platform.
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estimation of Specific Cutting Energy in an s235 alloy for multi directional ultrasonic vibration assisted machining using the finite element method
Materials, 2020Co-Authors: Luis Carlos Florez Garcia, Hernan Alberto Gonzalez Rojas, Antonio Sanchez J EgeaAbstract:The objective of this work is to analyze the influence of the vibration-assisted turning process on the machinability of S235 carbon steel. During the experiments using this vibrational machining process, the vibrational amplitude and frequency of the Cutting tool were adjusted to drive the tool tip in an elliptical or linear motion in the feed direction. Furthermore, a finite element analysis was deployed to investigate the mechanical response for different vibration-assisted Cutting conditions. The results show how the Specific Cutting Energy and the material's machinability behave when using different operational Cutting parameters, such as vibration frequency and tool tip motion in the x-axis, y-axis, and elliptical (x-y plane) motion. Then, the Specific Cutting Energy and material's machinability are compared with a conventional turning process, which helps to validate the finite element method (FEM) for the vibration-assisted process. As a result of the operating parameters used, the vibration-assisted machining process leads to a machinability improvement of up to 18% in S235 carbon steel. In particular, higher vibration frequencies were shown to increase the material's machinability due to the Specific Cutting Energy decrease. Therefore, the finite element method can be used to predict the vibration-assisted Cutting and the Specific Cutting Energy, based on predefined Cutting parameters.
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influence of the regime of electropulsing assisted machining on the plastic deformation of the layer being cut
Materials, 2018Co-Authors: Saqib Hameed, Hernan Alberto Gonzalez Rojas, Josep Ignasi Perat Benavides, Amelia Napoles Alberro, Antonio Sanchez J EgeaAbstract:In this article, the influence of electropulsing on the machinability of steel S235 and aluminium 6060 has been studied during conventional and electropulsing-assisted turning processes. The machinability indices such as chip compression ratio ξ , shear plane angle ϕ and Specific Cutting Energy (SCE) are investigated by using different Cutting parameters such as Cutting speed, Cutting feed and depth of cut during electrically-assisted turning process. The results and analysis of this work indicated that the electrically-assisted turning process improves the machinability of steel S235, whereas the machinability of aluminium 6060 gets worse. Finally, due to electropluses (EPs), the chip compression ratio ξ increases with the increase in Cutting speed during turning of aluminium 6060 and the SCE decreases during turning of steel S235.
Yung C. Shin - One of the best experts on this subject based on the ideXlab platform.
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experimental evaluation of laser assisted machining of silicon carbide particle reinforced aluminum matrix composites
The International Journal of Advanced Manufacturing Technology, 2013Co-Authors: Chinmaya R Dandekar, Yung C. ShinAbstract:An experimental study on machining of a particle-reinforced metal matrix composite (MMC) subjected to laser-assisted machining (LAM) was conducted. The MMC studied is an A359 aluminum matrix composite reinforced with 20 % by volume fraction silicon carbide particles. LAM was evaluated experimentally for its potential to improve machinability while minimizing the subsurface damage. The effectiveness of LAM was studied by measuring the Cutting forces, Specific Cutting Energy, surface roughness, subsurface damage, and tool wear under various material removal temperatures (Tmr). The optimum Tmr is established as 300 °C, with LAM providing a 37 % reduction in the surface roughness, a 12 % reduction in the Specific Cutting Energy, and 1.7–2.35 times improvement in tool life over conventional machining dependent on the Cutting speed.
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laser assisted machining of a fiber reinforced metal matrix composite
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2010Co-Authors: Chinmaya R Dandekar, Yung C. ShinAbstract:Metal matrix composites, due to their excellent properties of high Specific strength, fracture resistance, and corrosion resistance, are highly sought after over their nonferrous alloys, but these materials also present difficulty in machining. Excessive tool wear and high tooling costs of diamond tools make the cost associated with machining of these composites very high. This paper is concerned with the machining of high volume fraction long-fiber metal matrix composites (MMCs), which has seldom been studied. The composite material considered for this study is an Al―2% Cu aluminum matrix composite reinforced with 62% by volume fraction alumina fibers (Al―2% Cu/Al 2 O 3 ). Laser-assisted machining (LAM) is utilized to improve the tool life and the material removal rate while minimizing the subsurface damage. The effectiveness of the laser-assisted machining process is studied by measuring the Cutting forces, Specific Cutting Energy, surface roughness, subsurface damage, and tool wear under various material removal temperatures. A multiphase finite element model is developed in ABAgUS/STANDARD to assist in the selection of Cutting parameters such as tool rake angle, Cutting speed, and material removal temperature. The multiphase model is also successful in predicting the damage depth on machining. The optimum material removal temperature is established as 300°C at a Cutting speed of 30 m/min. LAM provides a 65% reduction in the surface roughness, Specific Cutting Energy, tool wear rate, and minimum subsurface damage over conventional machining using the same Cutting conditions.
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laser assisted machining of a fiber reinforced metal matrix composite
ASME 2009 International Manufacturing Science and Engineering Conference Volume 2, 2009Co-Authors: Chinmaya R Dandekar, Yung C. ShinAbstract:Metal matrix composites due to their excellent properties of high Specific strength, fracture resistance and corrosion resistance are highly sought after over their non-ferrous alloys, but these materials also present difficulty in machining. Excessive tool wear and high tooling costs of diamond tools makes the cost associated with machining of these composites very high. This paper is concerned with machining of high volume fraction long-fiber MMC’s, which has seldom been studied. The composite material considered for this study is an Al-2%Cu aluminum matrix composite reinforced with 62% by volume fraction alumina fibers (Al-2%Cu/Al2 O3 ). Laser-machining is utilized to improve the tool life and the material removal rate while minimizing the sub-surface damage. The effectiveness of the laser-assisted machining process is studied by measuring the Cutting forces, Specific Cutting Energy, surface roughness, sub-surface damage and tool wear under various material removal temperatures. A multi-phase finite element model is developed in ABAQUS/Standard to identify and assist in selection of Cutting parameters such as; tool rake angle, Cutting speed and material removal temperature. The multi-phase model is also successful in predicting the damage depth on machining. The optimum material removal temperature is established as 300°C at a Cutting speed of 30 m/min. LAM provides a 65% reduction in the surface roughness, Specific Cutting Energy, the tool wear rate and minimum sub-surface damage over conventional machining using the same Cutting conditions.Copyright © 2009 by ASME
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laser assisted machining of inconel 718 with an economic analysis
International Journal of Machine Tools & Manufacture, 2006Co-Authors: Mark R Anderson, Rahul Patwa, Yung C. ShinAbstract:Abstract Superalloys have high strengths at elevated temperatures, which make them attractive toward various applications and also make these materials difficult to machine at room temperature due to excessive tool wear and poor surface finish. Laser-assisted machining (LAM) offers the ability to machine superalloys more efficiently and economically by providing the local heating of the workpiece prior to material removal by a single point Cutting tool. An existing transient, three-dimensional heat transfer model is modified for modeling LAM of Inconel 718. Suitable coating conditions are determined for increasing the laser absorptivity in metals and an approximate absorptivity value is determined. The thermal model is validated in axial and circumferential directions by temperature measurement using an infrared camera. The machinability of Inconel 718 under varying conditions is evaluated by examining tool wear, forces, surface roughness, and Specific Cutting Energy. With increasing material removal temperature from room temperature to 620 °C, the benefit of LAM is demonstrated by a 25% decrease in Specific Cutting Energy, a 2–3-fold improvement in surface roughness and a 200–300% increase in ceramic tool life over conventional machining. Moreover, an economic analysis shows significant benefits of LAM of Inconel 718 over conventional machining with carbide and ceramic inserts.
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laser assisted machining of magnesia partially stabilized zirconia
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2004Co-Authors: Frank E Pfefferkorn, Yung C. Shin, Yinggang Tian, F P IncroperaAbstract:Laser-assisted machining (LAM) of magnesia-partially-stabilized zirconia (PSZ) is investigated to determine the effect of heating on machinability, as determined by tool wear, Cutting Energy, surface integrity, and material removal mechanisms. It is found that PSZ can be successfully machined with a polycrystalline cubic boron nitride tool and that tool life increases with material removal temperature up to a maximum of 121 minutes. The benefit of laser-assistance in material removal is also demonstrated by the 2.5 fold decrease in the Specific Cutting Energy with increased temperature. It is shown surface roughness varies significantly with tool wear with little dependence on Cutting temperature unlike in LAM of other ceramics. Evidence of mixed brittle and ductile material removal mechanisms is presented, and the optimum condition within the test matrix is established.
Bing Wang - One of the best experts on this subject based on the ideXlab platform.
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Proper selection of Cutting parameters and Cutting tool angle to lower the Specific Cutting Energy during high speed machining of 7050-T7451 aluminum alloy
Journal of Cleaner Production, 2016Co-Authors: Bing Wang, Qinghua Song, Zhanqiang Liu, Yi Wan, Zhenyu ShiAbstract:Cleaner production and sustainability are of vital importance in the field of machining processes where great amount of Energy is consumed. Reducing the Energy consumption during machining process can significantly improve the environmental and economical performance of manufacturing systems. To achieve this, calculation of Energy consumption during the metal Cutting process is required. This paper investigates the Specific Cutting Energy consumption for the serrated chip formation of 7050-T7451 aluminum alloy in high speed machining. The Cutting Energy consumption during serrated chip formation mainly includes such three components as plastic deformation Energy in the primary deformation zone, friction work between the tool-chip interface and kinetic Energy of the flowing chip. The predictive models of these three Energy components are developed for orthogonal Cutting mode, and the influences of Cutting speed, undeformed chip thickness and tool rake angle on the Cutting Energy consumption are revealed. Meanwhile, the theoretical Energy consumptions under different undeformed chip thicknesses are validated with the high speed orthogonal Cutting experiments of 7050-T7451 aluminum alloy. Based on the research results, when high Cutting speeds are applied in order to improve the machining efficiency, large positive rake angle tools and large undeformed chip thicknesses are recommended if the rigidity of the machining system and the machining surface quality can be guaranteed.
Choon Man Lee - One of the best experts on this subject based on the ideXlab platform.
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a study on the Energy efficiency of Specific Cutting Energy in laser assisted machining
Applied Thermal Engineering, 2016Co-Authors: Jong Wook Ahn, Wan Sik Woo, Choon Man LeeAbstract:Abstract As hybrid machining approach, laser assisted machining (LAM) is a processing method used to improve productivity and surface quality, in which the workpiece is softened by laser preheating. LAM is also an effective method to save Cutting Energy by reducing Cutting forces. In this study, the Specific Cutting Energy was represented by tangential force and material removal rate (MRR). In order to analyze the thermal properties of the material, a thermal analysis was performed. The machining conditions were selected in accordance with the thermal analysis results. The Specific Cutting Energy was compared for each depth of cut depending on the spindle rotation speed and feed rate. When compared to conventional processing in all conditions, LAM exhibited a higher efficiency in Energy as well as the Cutting force.