A flexible multi-body model of a surface miner for analyzing the interaction between rock-cutting forces and chassis vibrations

The discontinuous nature of rock cutting can easily cause unwanted vibrations in the structure of a surface miner.If these vibrations are not properly addressed,the related stress cycles can gradually damage the chassis resulting in fatigue failures.These events can seriously undermine the safety of operators and digging operations may be stopped for days,with an obvious economic impact.This work presents an analysis of the dynamics of a surface miner,focusing on the interaction between cutting machine dynamics and cutting forces,which is a new approach for this type of machine.For this purpose,the authors developed a numerical model of the cutting process made up of(1)a multi-body model of the cutting machine,which takes into account the chassis's flexibility;(2)a model of the rotating cutting head;and(3)a model of the interaction between the cutting head and rock,based on Shao's model.The model was compared with experimental results and then used to investigate the effects of cutting speed and cutting depth on the machine dynamics.

A Model for Predicting Dynamic Cutting Forces in Sand Mould Milling with Orthogonal Cutting

Cutting force is one of the research hotspots in direct sand mould milling because the cutting force directly a ects the machining quality and tool wear. Unlike metals, sand mould is a heterogeneous discrete deposition material. There is still a lack of theoretical research on the cutting force. In order to realize the prediction and control of the cut?ting force in the sand mould milling process, an analytical model of cutting force is proposed based on the unequal division shear zone model of orthogonal cutting. The deformation velocity relations of the chip within the orthogonal cutting shear zone are analyzed first. According to the flow behavior of granular, the unequal division shear zone model of sand mould is presented, in which the governing equations of shear strain rate, strain and velocity are estab?lished. The constitutive relationship of quasi?solid–liquid transition is introduced to build the 2D constitutive equation and deduce the cutting stress in the mould shear zone. According to the cutting geometric relations of up milling with straight cutting edge and the transformation relationship between cutting stress and cutting force, the dynamic cutting forces are predicted for di erent milling conditions. Compared with the experimental results, the predicted results show good agreement, indicating that the predictive model of cutting force in milling sand mould is validated. Therefore, the proposed model can provide the theoretical guidance for cutting force control in high e ciency mill?ing sand mould.

Predictive Modeling and Parameter Optimization of Cutting Forces During Orbital Drilling

To optimize cutting control parameters and provide scientific evidence for controlling cutting forces,cutting force modeling and cutting control parameter optimization are researched with one tool adopted to orbital drill holes in aluminum alloy 6061.Firstly,four cutting control parameters(tool rotation speed,tool revolution speed,axial feeding pitch and tool revolution radius)and affecting cutting forces are identified after orbital drilling kinematics analysis.Secondly,hybrid level orthogonal experiment method is utilized in modeling experiment.By nonlinear regression analysis,two quadratic prediction models for axial and radial forces are established,where the above four control parameters are used as input variables.Then,model accuracy and cutting control parameters are analyzed.Upon axial and radial forces models,two optimal combinations of cutting control parameters are obtained for processing a13mm hole,corresponding to the minimum axial force and the radial force respectively.Finally,each optimal combination is applied in verification experiment.The verification experiment results of cutting force are in good agreement with prediction model,which confirms accracy of the research method in practical production.

Performances of a Stinger PDC cutter breaking granite: Cutting force and mechanical specific energy in single cutter tests

The Stinger PDC cutter has high rock-breaking efficiency and excellent impact and wear resistance, which can significantly increase the rate of penetration (ROP) and extend PDC bit life for drilling hard and abrasive formation. The knowledge of force response and mechanical specific energy (MSE) for the Stinger PDC cutter is of great importance for improving the cutter's performance and optimizing the hybrid PDC bit design. In this paper, 87 single cutter tests were conducted on the granite. A new method for precisely obtaining the rock broken volume was proposed. The influences of cutting depth, cutting angle, and cutting speed on cutting force and MSE were analyzed. Besides, a phenomenological cutting force model of the Stinger PDC cutter was established by regression of experimental data. Moreover, the surface topography and fracture morphology of the cutting groove and large size cuttings were measured by a 3D profilometer and a scanning electron microscope (SEM). Finally, the rock-breaking mechanism of the Stinger PDC cutter was illustrated. The results indicated that the cutting depth has the greatest influence on the cutting force and MSE, while the cutting speed has no obvious effects, especially at low cutting speeds. As the increase of cutting depth, the cutting force increases linearly, and MSE reduces with a quadratic polynomial relationship. When the cutting angle raises from 10° to 30°, the cutting force increases linearly, and the MSE firstly decreases and then increases. The optimal cutting angle for breaking rock is approximately 20°. The Stinger PDC cutter breaks granite mainly by high concentrated point loading and tensile failure, which can observably improve the rock breaking efficiency. The key findings of this work will help to reveal the rock-breaking mechanisms and optimize the cutter arrangement for the Stinger PDC cutter.

Cutting forces analysis of micro-milling process on Inconel 718-a finite element approach

This paper presents a modeling and simulation of micro-milling process with finite element modeling(FEM)analysis to predict cutting forces.The micro-milling of Inconel 718 is conducted using high-speed steel(HSS)micro-end mill cutter of 1mm diameter.The machining parameters considered for simulation are feed rate,cutting speed and depth of cut which are varied at three levels.The FEM analysis of machining process is divided into three parts,i.e.,pre-processer,simulation and post-processor.In preprocessor,the input data are provided for simulation.The machining process is further simulated with the pre-processor data.For data extraction and viewing the simulated results,post-processor is used.A set of experiments are conducted for validation of simulated process.The simulated and experimental results are compared and the results are found to be having a good agreement.

Experimental Investigation of Material Removal in Elliptical Vibration Cutting of Cortical Bone

To benefit tissue removal and postoperative rehabilitation,increased efficiency and accuracy and reduced operating force are strongly required in the osteotomy.A novel elliptical vibration cutting(EVC)has been introduced for bone cutting compared with conventional cutting(CC)in this paper.With the assistance of high-speed microscope imaging and the dynamometer,the material removals of cortical bone and their cutting forces from two cutting regimes were recorded and analysed comprehensively,which clearly demonstrated the chip morphology improvement and the average cutting force reduction in the EVC process.It also revealed that the elliptical vibration of the cutting tool could promote fracture propagation along the shear direction.These new findings will be of important theoretical and practical values to apply the innovative EVC process to the surgical procedures of the osteotomy.

Cutting Force Fluctuation Suppression and Error Homogenization of Noncircular Gear Hobbing Based on the Tool Shifting Method

The current research on noncircular hobbing mainly focuses on the linkage model and motion realization.However,the intermittent cutting characteristics of hobbing would increase uncertainties in the manufacturing process.In this paper,a hobbing machining model with tool-shifting characteristics was proposed to solve the problems of cutting force fluctuation and inconsistency of tooth profile envelope accuracy at different positions of the pitch curve in noncircular gear hobbing.Based on the unit cutting force coefficient method,the undeformed chip volume generated by interrupted cutting was used to characterize the fluctuation trend of the hobbing force.The fluctuation characteristics of the cutting force generated by different hobbing models were compared and analyzed.Using the equivalent gear tooth and hob slotting numbers,an analysis model of the tooth profile envelope error of the noncircular gear was constructed.Subsequently,the tooth profile envelope errors at different positions of the pitch curve were compared and analyzed based on the constructed model.The transmission structure of the electronic gearbox was constructed based on the proposed hobbing model,and the hobbing experiment was conducted based on the selfdeveloped noncircular gear CNC hobbing system.This paper proposes a hobbing method that can effectively suppress the fluctuation of the peak and whole circumference cutting force and reduce the maximum envelope error of the whole circumference gear teeth.

Experimental investigation on the cuttings formation process and its relationship with cutting force in single PDC cutter tests

The single polycrystalline diamond compact(PDC)cutter test is widely used to investigate the mecha-nism of rock-breaking.The generated cuttings and cutting force are important indexes reflecting the rock failure process.However,they were treated as two separate parameters in previous publications.In this study,through a series of rock block cutting tests,the relationship between them was investigated to obtain an in-depth understanding of the formation of cuttings.In addition,to validate the standpoints obtained in the aforementioned experiments,rock sheet cutting tests were conducted and the rock failure process was monitored by a high-speed camera frame by frame.The cutting force was recorded with the same sampling rate as the camera.By this design,every sampled point of cutting force can match a picture captured by the camera,which reflects the interaction between the rock and the cutter.The results indicate that the increase in cutting depth results in a transition of rock failure modes.At shallow cutting depth,ductile failure dominates and all the cuttings are produced by the compression of the cutter.The corresponding cutting force fluctuates slightly.However,beyond the critical depth,brittle failure occurs and chunk-like cuttings appear,which leads to a sharp decrease in cutting force.After that,the generation of new surface results in a significant decrease in actual cutting depth,a parameter proposed to reflect the interaction between the rock and the cutter.Consequently,ductile failure dominates again and a slight fluctuation of cutting force can be detected.As the cutter moves to the rock,the actual cutting depth gradually increases,which results in the subsequent generation of chunk-like cuttings.It is accompanied by an obvious cutting force drop.That is,ductile failure and brittle failure,one following another,present at large cutting depth.The transition of rock failure mode can be correlated with the variation of cutting force.Based on the results of this paper,the real-time monitoring of torque may be helpful to determine the efficiency of PDc bits in the downhole.

Research on the Characters of the Cutting Force in Vibration Cutting Particle Reinforced Metal Matrix Composites SiC_p/Al

In this paper, turning experiments of machining particle reinforced metal matri x composites(PRMMCs) SiC p/Al with PCD tools have been carried out. The cutting force characteristics in ultrasonic vibration turning compared with that in com mon turning were studied. Through the single factor experiments and multiple fac tor orthogonal experiments, the influences of three kinds of cutting conditions such as cutting velocity, amount of feed and cutting depth on cutting force were analyzed in detail. Meanwhile, according to the experimental data, the empirica l formula of main cutting force in ultrasonic vibration turning was conclude d. According to the test results, the cutting force is direct proportion to cutt ing depth basically according to the relation between cutting force and other fa ctors, which is similar to that of common cutting, so is the feed rate, but the influence is not so big. The influence of cutting speed is larger than that of f eed rate on cutting force because the efficient cutting time increases in vibrat ion cycle with the increase of cutting speed, which causes cutting force to incr ease. The research results indicate: (1) Ultrasonic vibration turning possesses much lower main cutting force than that in common turning when adopting smaller cutting parameters. If using larger cutting parameters, the difference will inco nspicuous. (2) There are remarkable differences of cutting force-cutting veloci ty characteristics in ultrasonic vibration turning from that in common turning m ainly because built-up edge does not emerge in ultrasonic turning unlike common turning in corresponding velocity range. (3) In ultrasonic vibration cutting, t he influence of cutting velocity on cutting force is most obvious among thre e cutting parameters and the influence of feed is smallest. So adopting lower cu tting velocity and larger cutting depth not only can reduce cutting force effect ively but also can ensure cutting efficiency. (4) The conclusions are useful in precision and super precision manufacturing thin-wall pieces.

Cutting performance of micro-textured PCBN tool

To study the efect of micro-texture on the cutting performance of polyrystalline cubic boron nitide(PCBN)tools,five types of micro-textures(circular pits,eliptical grooves,transverse grooves,composite grooves,and wavy grooves)were applied to the rake surface of PCBN tools by an optical fber laser marking machine.Through a combination of three dimensional cutting simulations and experiments,the influences of micro-texture on chip-tool contact area,cutting force,chip morphology,shear angle,and surface roughness during the cuting process were analyzed.The results indicated that the chip--tool contact area and cutting force of both non-textured and micro textured tools increased with increasing cutting speed,while the shear angle decreased with increasing cutting speed.The chip-tool contact area and cutting force of the five types of micro-textured tools were smaller than those of the non textured tool The chip-tool contact area and cutting force obtained by the wavy-groove micro textured tool were the smallest.The chip radius produced by the five types of micro-textured tools was smaller than that produced by the non-textured tool,and the chip morphology was more stable.The transverse-groove micro-textured tool had a better chip breaking efect.The chip rnadius generated by the lliptical groove micro textured tool was 0.96 cm,while that generated by the wavy-groove tool varied from 0.55 cm to 1.26 cm.The presence of a micro-texture reduced the surface roughness of the workpiece by 11.73%-56.7%.Under the same cutting conditions,the five types of micro-textured tools gave a smaller chip--tool contact area,cutting force,chip radius,and surface roughness and a larger shear angle than the non-textured tool.In addition,the elliptical groove and wavy-groove micro-textured tools had better cuting performance.

Study on Cutting Force,Cutting Temperature and Machining Residual Stress in Precision Turning of Pure Iron with Different Grain Sizes

Pure iron is one of the difficult-to-machine materials due to its large chip deformation,adhesion,work-hardening,and built-up edges formation during machining.This leads to a large workpiece deformation and challenge to meet the required technical indicators.Therefore,under varying the grain size of pure iron,the influence of cutting speed,feed,and depth of cut on the cutting force,heat generation,and machining residual stresses were explored in the turning process to improve the machinability without compromising the mechanical properties of the material.The experimental findings have depicted that the influence of grain size on cutting force in the precision turning process is not apparent.However,the cutting temperature and residual stress of machining fine-grain iron were much smaller than the coarse grain at all levels of cutting parameters.

Numerical simulation of coal wall cutting and lump coal formation in a fully mechanized mining face

It is difficult to accurately calculate the lump coal rate in a fully mechanized mining face.Therefore,a numerical simulation of the coal wall cutting process,which revealed the crack expansion,development,evolution in the coal body and the corresponding lump coal formation mechanism,was performed in PFC2D.Moreover,a correlation was established between the cutting force and lump coal formation,and a statistical analysis method was proposed to determine the lump coal rate.The following conclusions are drawn from the results:(1)Based on a soft ball model,a coal wall cutting model is established.By setting the roller parameters based on linear bonding and simulating the roller cutting process of the coal body,the coal wall cutting process is effectively simulated,and accurate lump coal rate statistics are provided.(2)Under the cutting stress,the coal body in the working face underwent three stages—microfracture generation,fracture expansion,and fracture penetration—to form lump coal,in which the fracture direction is orthogonal to the cutting pressure chain.Within a certain range from the roller,as the cutting depth of the roller increased,the number of new fractures in the coal body first increases and then stabilizes.(3)Under the cutting stress,the fractured coal body is locally compressed,thereby forming a compact core.The formation and destruction of the compact core causes fluctuations in the cutting force.The fluctuation amplitude is positively related to the coal mass.(4)Because the simulation does not consider secondary damage in the coal,the simulated lump coal rate is larger than the actual lump coal rate in the working face;this deviation is mainly concentrated in large lump coal with a diameter greater than 300 mm.

Prediction of cutting force in ultra-precision machining of nonferrous metals based on strain energy

The effects of the nonuniform cutting force and elastic recovery of processed materials in ultra-precision machining are too complex to be treated using traditional cutting theories,and it is necessary to take account of factors such as size effects,the undeformed cutting thickness,the tool blunt radius,and the tool rake angle.Therefore,this paper proposes a new theoretical calculation model for accurately predicting the cutting force in ultra-precision machining,taking account of such factors.The model is first used to analyze the material deformation of the workpiece and the cutting force distribution along the cutting edge of a diamond tool.The size of the strain zone in different cutting deformation zones is then determined by using the distribution of strain work per unit volume and considering the characteristics of the stress distribution in these different deformation zones.Finally,the cutting force during ultra-precision machining is predicted precisely by calculating the material strain energy in different zones.A finite element analysis and experimental data on ultra-precision cutting of copper and aluminum are used to verify the predictions of the theoretical model.The results show that the error in the cutting force between the calculation results and predictions of the model is less than 14%.The effects of the rake face stress distribution of the diamond tool,the close contact zone,and material elastic recovery can be fully taken into account by the theoretical model.Thus,the proposed theoretical calculation method can effectively predict the cutting force in ultra-precision machining.

Identifying Optimal Cutting Parameters in Drilling of Titanium Aluminum Vanadium Using Finite Element Analysis

Titanium alloys are widely used in the aerospace industries because of their excellent strength-to-weight ratio, high resistance to corrosion, high chemical reactivity and low thermal conductivity and ability to withstand high temperatures. However, these properties make titanium alloys difficult to machine. Drilling of titanium alloy may generate high temperature and high cutting forces. This paper is aimed at determining the suitable cutting parameters in the drilling of titanium alloys to minimize the cutting temperature and cutting forces. A finite element 3D model of the drilling process is simulated in this research. A combination of drilling speeds and feed rates are simulated to obtain the resulting responses of cutting force and temperature. The central composite design (CCD) is used to generate different combinations of cutting parameters to reduce the number of experiments and optimize the temperature and cutting force responses. Results show at the drilling speed of 5000 rpm with a feed rate of 0.1 mm/rev, temperature and cutting force significantly reduced.

Cutting Characteristics of Force Controllable Milling Head

In order to control cutting force and its direction i n milling operation, a new milling head was developed. The head has two milling cutters, which are connected by a pair of gears and rotate in opposite direction respectively. Both up-cut and down-cut can be carried out simultaneously by t hese milling cutters. The each depth of cut, the ratio of up/down cutting depth , by these cutters can be also selected. The cutting force characteristics were experimentally discussed by changing the ratio. The cutting force and its locus can be also changed by the selection of the ratio of up/down cutting depth. For practical usage of the head the analytical prediction method of the cutting forc e characteristics under selected cutting condition was proposed based on the ene rgy approach method proposed, in which both of cutting force characteristics of a single milling cutter and the combined milling cutter under a selected up/dow n cutting depth ratio were analytically estimated based on the two dimensional c utting data. It was experimentally shown that in NC milling machine the cutting force locus was controlled in pre-determined direction under various tool paths .

Influence of Cutting and Geometrical Parameters on the Cutting Force in Milling

This paper presents a numerical modelling of the dynamic behaviour of the Machine-Tool-Part system (MOP) in milling. The numerical study of such complex structure requires the use of sophisticated method like finite elements one. Simulation is employed to predict cutting forces and dynamic response of Machine-Tool-Part system (MOP) during end-milling operation. Finally, spectral analysis is presented to see the influence of feed direction in the vibration.

Generating micro/nanostructures on magnesium alloy surface using ultraprecision diamond surface texturing process

The lightness and high strength-to-weight ratio of the magnesium alloy have attracted more interest in various applications.However,micro/nanostructure generation on their surfaces remains a challenge due to the flammability and ignition.Motivated by this,this study proposed a machining process,named the ultraprecision diamond surface texturing process,to machine the micro/nanostructures on magnesium alloy surfaces.Experimental results showed the various microstructures and sawtooth-shaped nanostructures were successfully generated on the AZ31B magnesium alloy surfaces,demonstrating the effectiveness of this proposed machining process.Furthermore,sawtooth-shaped nanostructures had the function of inducing the optical effect and generating different colors on workpiece surfaces.The colorful letter and colorful flower image were clearly viewed on magnesium alloy surfaces.The corresponding cutting force,chip morphology,and tool wear were systematically investigated to understand the machining mechanism of micro/nanostructures on magnesium alloy surfaces.The proposed machining process can further improve the performances of the magnesium alloy and extend its functions to other fields,such as optics.

Effect of aluminum content on machining characteristics of AZ31 and AZ91 magnesium alloys during drilling

Magnesium(Mg)and its alloys are now becoming the promising choice for various structural applications due to their low density and high specific strength compared with other light metals such as aluminum and its alloys.Among all Mg alloys,AZ(aluminum and zinc)series is the most widely used alloy system for various structural applications.But,machining of magnesium and its alloys involves certain issues due to their brittle nature and risk of inflammability unlike other nonferrous metals.Particularly,alloys with considerable amount of secondary phase may exhibit different machining characteristics during metal cutting operations.In the present study,two AZ series alloys AZ31 and AZ91 were selected and drilling operation was performed to assess the effect of the secondary phase amount and distribution on machining characteristics.Drilling operation was carried out at different sets of process parameters and cutting forces were obtained and the chips which have been produced during drilling were analyzed.From the results,it can be clearly understood that the presence of secondary phase(Mg_(17)Al_(12))has a significant influence on cutting forces.Increase in cutting speed has reduced the required cutting force and load fluctuations in all the cases.

Experiment on Machinability of Ti2AlNb Intermetallic Alloy

Ti2AlNb intermetallic alloy is a newly developed high-temperature resistant structural material due to its excellent material and mechanical properties,which also make it to be one of the most difficult-to-cut materials.In order to study the machinability of Ti2AlNb alloy,a series of turning experiments of Ti2AlNb alloy with varying cutting speed and feed rate using coated carbide tools are carried out.The results associated with cutting forces,cutting temperature and tool wear are presented and discussed.Moreover,the cutting performance of Ti2AlNb alloy is evaluated in comparison with that of most commonly used Ti6Al4 Vand Inconel 718 alloys in terms of the cutting forces and cutting temperature.The comparison results show that there is a correlation between the machinability and the mechanical properties of work material properties.Additionally,considering material removal rate and tool life,the optimized machining parameters for cutting Ti2AlNb alloys using coated carbide tools are recommended.

Feasibility study of wave-motion milling of carbon fiber reinforced plastic holes

Carbon fiber reinforced plastic(CFRP)has been applied in aeronautics,aerospace,automotive and medical industries due to its superior mechanical properties.However,due to its difficult-to-cut characteristic,various damages in twist drilling and chip removal clog in core drilling could happen,inevitably reducing hole quality and hole-manufacturing efficiency.This paper proposes the wave-motion milling(WMM)method for CFRP hole-manufacturing to improve hole quality.This paper presents a motion path model based on the kinematics of the WMM method.The wave-motion cutting mode in WMM was analyzed first.Then,comparison experiments on WMM and conventional helical milling(CHM)of CFRP were carried out under dry conditions.The results showed that the hole surface quality of the CFRP significantly improved with a decrease of 18.1%–36%of Ra value in WMM compared to CHM.WMM exerted a significantly weaker thrust force than that of CHM with a reduction of 12.0%–24.9%and 3%–7.7%for different axial feed per tooth and tangential feed per tooth,respectively.Meanwhile,the hole exit damages significantly decreased in WMM.The average tear length at the hole exit in WMM was reduced by 3.5%–29.5%and 35.5%–44.7%at different axial feed per tooth and tangential feed per tooth,respectively.Moreover,WMM significantly alleviated tool wear.The experimental results suggest that WMM is an effective and promising strategy for CFRP hole-manufacturing.