Edge Forces in Metal Cutting: Fundamental Analysis and Experimental Verification

Rimah S. Al Aridi, American University of Beirut, Mechanical Engineering Department, P.O. Box 11-0236, Riad El-Solh, Beirut 1107 2020, Lebanon, Email: rsa87@mail.aub.edu

Ahmad M. R. Baydoun, American University of Beirut Mechanical Engineering Department P.O. Box 11-0236, Riad El-Solh Beirut 1107 2020, Lebanon, Email: amb52@mail.aub.edu       

Ramsey F. Hamade, American University of Beirut, Mechanical Engineering Department, P.O. Box 11-0236, Riad El-Solh, Beirut 1107 2020, Lebanon, Email: rh13@aub.edu.lb

In metal cutting, some of the generated forces do not contribute to chip formation, referred to as parasitic or plowing forces, these forces are induced mainly as a result of the finite sharpness of the tool (cutting edge radius) and the tool's land (flank). Determining the magnitude of the parasitic forces is essential for understanding the mechanics and physics of machining operations conducted at minimal feed values such as micro-machining and vibration-assisted- micro-machining. This research estimates the magnitude of the parasitic forces by employing analytical and numerical simulations. An analytical model is developed based on a cylindrical indentation model, which is verified by extensive cutting experiments.

The model characterizing parasitic forces for 2D orthogonal cutting takes into consideration all the parameters affecting the process from feeds, cutting speeds, rake angle, temperature, and cutting-edge radius. The experimental validation, designed to measure the parasitic forces, was performed on the HAAS SL 20 CNC machine. A Kistler 5070 charge amplifier is used to acquire and amplifies the signal emanating from a dynamometer, which is then collected by a custom Kistler software. The amplifier possesses a typical error percentage of just 0.3 % with a maximum of 1 % and a sampling rate to be input at 1000 Hz. The experiments were conducted at a spindle speed range of 30 m/min to 150 m/min while the feed range was 0.5 µm and 10 µm.

 

The plowing forces are found to be significantly affected by the feed parameter, with increases in the feed value resulting in increases in the plowing forces. The friction coefficient was related to the machining temperature and cutting speed. The experimental validation shows that the proposed model is able to predict the magnitude of the parasitic forces, with an average percent difference of 3.095 %. This model can thus be used to accurately estimates the parasitic forces and help in the selection of cutting parameters for the low feed cutting operations, resulting in a clearer understanding of the machining process.  

 

 


Edge Forces in Metal Cutting: Fundamental Analysis and Experimental Verification

Division / Sponsors: 
Aerospace, Bioengineering, Applied Mechanics, Design Engineering Division, Advanced Energy Systems, Manufacturing Engineering Division, Noise Control and Acoustics, Nondestructive Evaluation, Diagnosis, and Prognosis (NDPD), Nuclear Engineering Division, Process Industries Division, Fluids Engineering, Heat Transfer, Materials, Microelectromechanical Systems, Safety Engineering and Risk Analysis, Computers & Information in Engineering


Paper Proceedings: https://asmedigitalcollection.asme.org/IMECE/IMECE2020/volume/84478

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