Geometrical analysis of thread milling – Part 1: Evaluation of tool angles

Thread milling is a method which is increasingly used for machining thread. For this operation, a helical interpolation is required. Furthermore, the thread mill is a tool whose geometry is rather complex. Its envelope profile is linked to the thread profile and a single tooth of the thread mill is composed of three continuous cutting edges. The present study proposes a geometrical model and an analytical formulation to define the rake face and the cutting edge. Further, the calculations of cutting planes and cutting angles are explained. The analysis shows specific aspects of thread mills, in particular the fact that the flute angle may lead to a negative rake angle. This study is a contribution to cutting geometry aspect and constitutes a step for cutting force model in thread milling

Tool wear monitoring and hole surface quality during CFRP drilling

The present investigation focuses on the evaluation of tool wear and surface integrity in the context of CFRP cutting. Series of drilling experiments were performed on CFRP plates using cemented carbide solid drills with the aim to investigate correlations between tool damage, cutting forces, temperature and hole surface quality. In particular, a new methodology has been developed to measure the drilling temperature and to assess the quality of the hole surfaces where occurred uncut fibers. As the surface roughness criterion is not relevant for such work materials, a discussion on the definition of the surface topography is proposed for CFRP work material

Investigation of tool geometry effect and penetration strategies on cutting forces during thread milling

The application of thread milling is increasing in industry because of its inherent advantages over other thread cutting techniques. The objective of this study is to investigate the effect of milling cutter tool geometry on cutting forces during thread milling. The proposed method can compare the performance of milling cutters in spite of the different number of tooth. The best thread milling cutter among the studied tools was determined from the cutting forces point of view. Furthermore, this study also pinpoints the best penetration strategy that provides minimum cutting forces. Lower cutting force variations will lead to fewer vibrations of the tool which in turn will produce accurate part.Postdoc de V Sharma financé par la région Bourgogn

An Innovative Experimental Study of Corner Radius Effect on Cutting Forces

The cutting forces are often modelled using edge discretisation methodology. In finish turning, due to the smaller corner radii, the use of a local cutting force model identified from orthogonal cutting tests poses a significant challenge. In this paper, the local effect of the corner radius on the forces is investigated using a new experimental configuration: corner cutting tests involving the tool nose. The results are compared with inverse identifications based on cylindrical turning tests and elementary cutting tests on tubes. The results obtained from these methods consistently show the significant influence of the corner radius on the cutting forces

Geometrical analysis of thread milling – Part 1: Evaluation of tool angles

Thread milling is a method which is increasingly used for machining thread. For this operation, a helical interpolation is required. Furthermore, the thread mill is a tool whose geometry is rather complex. Its envelope profile is linked to the thread profile and a single tooth of the thread mill is composed of three continuous cutting edges. The present study proposes a geometrical model and an analytical formulation to define the rake face and the cutting edge. Further, the calculations of cutting planes and cutting angles are explained. The analysis shows specific aspects of thread mills, in particular the fact that the flute angle may lead to a negative rake angle. This study is a contribution to cutting geometry aspect and constitutes a step for cutting force model in thread milling

An Experimental and Analytical Method for Investigating Plastic Flow in Form Tapping

While threaded holes made by cutting taps result in material removal, in form tapping, the tap displaces the work material by plastic flow to form the thread section. The aim of the present work is to study, both experimentally and analytically, the 3D-plastic flow in form tapping of low-alloy steels. An experimental technique for producing and measuring the 3D displacement is proposed. Experimental results of displacements are used in the analytical analysis. The Green-Lagrange strain tensor is determined from the measurements obtained. The deviator stress tensor is calculated by using the constitutive law of the work material. The stress equilibrium allows the stress distribution resulting from the form tapping process. The results obtained show the quantification of the 3D-plastic flow, demonstrating that the external layer of the thread is strongly deformed. KEY WORDS: form tapping, plastic flow, thread formation

A force model for superfinish turning of pure copper with rounded edge tools at low feed rate

International audienceThis paper presents a model for force prediction of superfinish turning operation on pure copper. The model is divided in two parts. The first part computes the forces acting on the rake face of the tool. The second part computes the forces on the clearance face that are much more important in superfinish machining than in conventional machining

Tool-life and wear mechanisms of CBN tools in machining of Inconel 718

The demand for increasing productivity when machining heat resistant alloys has resulted in the use of new tool materials such as cubic boron nitride (CBN) or ceramics. However, CBN tools are mostly used by the automotive industry in hard turning, and the wear of those tools is not sufficiently known in aerospace materials. In addition, the grade of these tools is not optimized for superalloys due to these being a small part of the market, although expanding (at 20% a year). So this investigation has been conducted to show which grade is optimal and what the wear mechanisms are during finishing operations of Inconel 718. It is shown that a low CBN content with a ceramic binder and small grains gives the best results. The wear mechanisms on the rake and flank faces were investigated. Through SEM observations and chemical analysis of the tested inserts, it is shown that the dominant wear mechanisms are adhesion and diffusion due to chemical affinity between elements from workpiece and insert

Cutting Forces Modeling in Finish Turning of Inconel 718 Alloy with Round Inserts

In turning, the applied forces have to be known as accurately as possible, especially in the case of difficult-to-cut materials for aircraft workpieces finishing operations. Traditionally, edge discretisation methodology based on local cutting laws is used to determine the cutting forces and results are usually considered suitable. Nevertheless, only the rake face is considered in most of studies and the cutting relations are determined by direct identification with a straight edge. This study deals with finishing operations of Inconel 718 alloy with one type of round insert. The main objective is to formulate a novel cutting forces model, taking into account the clearance face. First, a generic model based on a geometrical description using homogeneous matrix transformation is presented. Then, cutting coefficients are identified by inverse identification from experimental measurements distributed with an orthogonal design experiment including tool wear. Finally, modeling and experimental values of the cutting forces are compared and the identified model is analysed

From large-scale to micro machining: a review of force prediction models

International audienceIn this paper, a reviewof work performed in the area of force modelling in metal cutting processes is presented. Past and present trends are described and criticised to compare their relevance with current requirements. Several approaches are reviewed, such as empirical, mechanistic and analytical models. The models' ability to predict forces, from rough machining to finish machining, is analysed