Hostname: page-component-cd9895bd7-q99xh Total loading time: 0 Render date: 2024-12-23T14:29:53.923Z Has data issue: false hasContentIssue false
  • English
  • Français

Prediction of Cutting Forces in Milling Stainless Steels using Chamfered Main Cutting Edge Tool

Published online by Cambridge University Press:  05 May 2011

C.-S. Chang
C.-S. Chang*
Affiliation:
Department of Mechanical Engineering, National Ilan University, I-Lan, Taiwan, 26014, R.O.C.
*
* Professor
Get access

Abstract

To study the cutting forces, the carbide tip's surface temperature, and the mechanism of secondary chip and main chip formation of face milling stainless steel with a chamfered main cutting edge has been investigated. Theoretical values of cutting forces were calculated and compared to the experimental results with SUS 304 stainless steel plate as a workpiece material. Force data from these tests were used to estimate the empirical constants of the mechanical model and to verify its prediction capabilities. A comparison of the predicted and measured forces shows good agreement. A preliminary discussion is also made for the design of special tool holders and their geometrical configurations. Next, the tips mounted in the tool holders are ground to a chamfered width and the tool dimensions are measured by using a toolmaker microscope.

Keywords

Face millingOblique cuttingChamfered main cutting edgeStainless steel
Type
Articles
Information
Journal of Mechanics , Volume 21 , Issue 3 , September 2005 , pp. 145 - 155
Copyright
Copyright © The Society of Theoretical and Applied Mechanics, R.O.C. 2005

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

1.Gray, A.G., Forming of Stainless Steels, Materials and Process Engineering Bookshelf, published by the American Society for Metals (ASM), USA, pp. 1–2 (1968).Google Scholar
2.Gu, F., Kapoor, S. G., DeVor, R. E. and Bandyopadhyay, P., ‘An Enhanced Cutting Force Model for Face Milling with Variable Cutter Feed Motion and Complex Workpiece Geometry,” Trans. of the ASME. J. of Manufacturing and Engineering, 119, pp. 467–476 (1997).Google Scholar
3.Martelloti, M. E., ‘An Analysis of the Milling Process,” Trans. of the ASME. J., Part II, 63, pp. 677–700 (1945).Google Scholar
4.Lin, T. R., “Reliability and Failure of Face-Milling Tools When Cutting Stainless Steel,” Journal of Materials Processing Technology, pp. 41–46 (1998).CrossRefGoogle Scholar
5.Shaw, M. C., Metal Cutting Principles, published by Oxford University Press, New York, pp. 335–367 (1984).Google Scholar
6.Hoshi, T., “Recent Development in Silver White-Chip (SWC) Cutting,” Proc. Int. Conf. on Cutting Tool Materials, Ford Mitchell, KY, USA, pp. 15–17 (1980).Google Scholar
7.Kim, H. S. and Ehmann, K. F., “A Cutting Force Model for Face Milling Operations,” Int. J. sof Machine Tool & Manufacturing, Design, Research and Application, 33(5), pp. 651–673 (1993).CrossRefGoogle Scholar
8.Kline, W. A., DeVor, R. E. and Lindberg, J. R., “The Prediction of Cutting Force in End Milling with Application to Cornering Cuts,” Int. J. Machine Tools & Manufacture, Design, Research and Application, 22(1), pp. 7–13 (1982).Google Scholar
9.Fu, H. J., DeVor, R. E. and Kapoor, S. G., “A Mechanistic Model for the Prediction of the Force System in Face Milling Operations,” Trans. of the ASME, 106, pp. 81–88 (1984).Google Scholar
10.Usui, E., Hirota, A. and Masuko, M., “Analytical Prediction of Three Dimensional Cutting Process: Part 1, Basic Cutting Model and Energy Approach,” Trans. of the ASME, 100, pp. 222–228 (1978).Google Scholar
11.Young, H. T., “Analysis of Force Pulsation in Intermittent Cut Operation,” The 5th National Conf. on Mechanical Engineering, CSME, Taipei, pp. 717–734 (1988).Google Scholar
12.Chang, C. S., “A Study of High Efficiency Face Milling Tools,” J. of Materials Processing Technology, 100, pp. 12–29 (2000).CrossRefGoogle Scholar
13.Pandey, P. C. and Shan, H. S., “Analysis of Cutting Forces in Peripheral and Face Milling Operations,” Int. J. Prod. Res., 10(4), pp. 379–388 (1972).CrossRefGoogle Scholar
14.Nakayama, K., Shaw, M. C., and Breuer, R. C., “Relationship between Forces, Temperatures Built-up Edge and Surface Finish,” Annals of CIRP, 14 pp. 211–233 (1966).Google Scholar
15.Chang, C. S., “Turning of Stainless Steel with Chamfered Main Cutting Edge Tools,” J. of Materials Processing Technology, 10(3), pp. 473–492 (1995).Google Scholar
16.Reklaitis, G. V., Ravindran, A. and Ragsdell, K. M., Region-Elimin. Method, Engineering Optima Methods and Application, Wiley-Interscience Press, New York, pp. 37–46 (1984).Google Scholar
17.Cook, N. H., The Mechanics of Chip Formation in Manufacturing Analysis, Addison-Wesley, New York, pp. 37–38 (1969).Google Scholar
18.Young, H. T., “Application of Predictive of Machining Theory to More Complicated Processes Including Single-Point Oblique Cutting Tools with Other than Single Straight Cutting Edges and Milling and Experimental Verification,” Ph.D. Dissertation, Universities of New Wales, Australia (1986).Google Scholar
19.Brookes, K. J. A., World Dictionary, Handbook of Hard Metals and Hard Materials, Int. Carbide Data Handbook, UK, pp. 10–12 (1992).Google Scholar