The Effect of the Tool Geometry and Cutting Conditions on the Tool Deflection and Cutting Forces
In this paper by measuring the cutting forces the effect
of the tool shape and qualifications (sharp and worn cutting tools of
both vee and knife edge profile) and cutting conditions (depth of cut
and cutting speed) in the turning operation on the tool deflection and
cutting force is investigated. The workpiece material was mild steel
and the cutting tool was made of high speed steel. Cutting forces
were measured by a dynamometer (type P.E.I. serial No 154). The
dynamometer essentially consisted of a cantilever structure which
held the cutting tool. Deflection of the cantilever was measured by an
L.V.D.T (Mercer 122) deflection indicator. No cutting fluid was used
during the turning operations. A modern CNC lathe machine (Okuma
LH35-N) was used for the tests. It was noted that worn vee profile
tools tended to produce a greater increase in the vertical force
component than the axial component, whereas knife tools tended to
show a more pronounced increase in the axial component.
[1] G. Boothroyd, W. Knight, Fundamentals of metal machining and
machine tools, 1st ed., Scripta Book Company, 1988.
[2] F. E. H. Tay, S. K. Sikdar, M. A. Mannan, Topography of the flank
wear surface, Journal of Materials Processing Technology 120 (2002)
243-248.
[3] D. A. Stephenson, J. S. Agapiou, Metal cutting theory and practice,
Marcel Dekker, INC., USA, 1997.
[4] V. C. Venkatesh, H. Chandrasekaran, Experimental techniques in metal
cutting, Prentice Hall of India Private Limited New Delhi, 1987.
[5] M. Cemal Cakir, Yahya Isik, Detecting tool breakage in turning aisi
1050 steelusing coated and uncoated cutting tools, Journal of Materials
Processing Technology 159 (2005) 191-198.
[6] S. K. Sikdar, M. Chen, Relationship between tool flank wear area and
component forces in single point turning, Journal of Materials
Processing Technology 128 (2002) 210-215.
[7] D.E. Dimla Sr., The impact of cutting conditions on cutting forces and
vibration signals in turning with plane face geometry inserts, Journal of
Materials Processing Technology 155-156 (2004) 1708-1715.
[8] Y. Isik, Investigating the machinability of tool steels in turning
operations, Materials and Design, 2006.
[9] C. Scheffer, H. Kratz, P. S. Heyns, and F. Klocke, Development of a
tool wear-monitoring system for hard turning, International Journal of
Machine Tools and Manufacture 43 (2003) 973-985.
[10] C. Chungchoo, D. Saini, The total energy and the total entropy of force
signals-new parameters for monitoring oblique turning operations,
International Journal of Machine Tools and Manufacture 40 (2000)
1879-1897.
[11] J. H. Lee, S. J. Lee, One-step-ahead prediction of flank wear using
cutting force, International Journal of Machine Tools and Manufacture
39 (1999) 1747-1760.
[12] V. C. Venkatesh, I. A. Kattan, D. Hoy, C. T. Ye, J. S. Vankirk, An
analysis of cutting tools with negative side cutting edge angles, Journal
of Materials Processing Technology 58 (1996) 351-361.
[13] H. V. Ravindra, Y. G. Srinivasa, R. Krishnamurthy, Modelling of tool
wear based on cutting forces in turning, Wear 169 (1993) 25-32.
[14] A. Bhattacharyya, Metal cutting theory and practice, Third Edition ,
New Central Book Agency (p), India, 1998.
[1] G. Boothroyd, W. Knight, Fundamentals of metal machining and
machine tools, 1st ed., Scripta Book Company, 1988.
[2] F. E. H. Tay, S. K. Sikdar, M. A. Mannan, Topography of the flank
wear surface, Journal of Materials Processing Technology 120 (2002)
243-248.
[3] D. A. Stephenson, J. S. Agapiou, Metal cutting theory and practice,
Marcel Dekker, INC., USA, 1997.
[4] V. C. Venkatesh, H. Chandrasekaran, Experimental techniques in metal
cutting, Prentice Hall of India Private Limited New Delhi, 1987.
[5] M. Cemal Cakir, Yahya Isik, Detecting tool breakage in turning aisi
1050 steelusing coated and uncoated cutting tools, Journal of Materials
Processing Technology 159 (2005) 191-198.
[6] S. K. Sikdar, M. Chen, Relationship between tool flank wear area and
component forces in single point turning, Journal of Materials
Processing Technology 128 (2002) 210-215.
[7] D.E. Dimla Sr., The impact of cutting conditions on cutting forces and
vibration signals in turning with plane face geometry inserts, Journal of
Materials Processing Technology 155-156 (2004) 1708-1715.
[8] Y. Isik, Investigating the machinability of tool steels in turning
operations, Materials and Design, 2006.
[9] C. Scheffer, H. Kratz, P. S. Heyns, and F. Klocke, Development of a
tool wear-monitoring system for hard turning, International Journal of
Machine Tools and Manufacture 43 (2003) 973-985.
[10] C. Chungchoo, D. Saini, The total energy and the total entropy of force
signals-new parameters for monitoring oblique turning operations,
International Journal of Machine Tools and Manufacture 40 (2000)
1879-1897.
[11] J. H. Lee, S. J. Lee, One-step-ahead prediction of flank wear using
cutting force, International Journal of Machine Tools and Manufacture
39 (1999) 1747-1760.
[12] V. C. Venkatesh, I. A. Kattan, D. Hoy, C. T. Ye, J. S. Vankirk, An
analysis of cutting tools with negative side cutting edge angles, Journal
of Materials Processing Technology 58 (1996) 351-361.
[13] H. V. Ravindra, Y. G. Srinivasa, R. Krishnamurthy, Modelling of tool
wear based on cutting forces in turning, Wear 169 (1993) 25-32.
[14] A. Bhattacharyya, Metal cutting theory and practice, Third Edition ,
New Central Book Agency (p), India, 1998.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:49695", author = "A. Fata and B. Nikuei", title = "The Effect of the Tool Geometry and Cutting Conditions on the Tool Deflection and Cutting Forces", abstract = "In this paper by measuring the cutting forces the effect
of the tool shape and qualifications (sharp and worn cutting tools of
both vee and knife edge profile) and cutting conditions (depth of cut
and cutting speed) in the turning operation on the tool deflection and
cutting force is investigated. The workpiece material was mild steel
and the cutting tool was made of high speed steel. Cutting forces
were measured by a dynamometer (type P.E.I. serial No 154). The
dynamometer essentially consisted of a cantilever structure which
held the cutting tool. Deflection of the cantilever was measured by an
L.V.D.T (Mercer 122) deflection indicator. No cutting fluid was used
during the turning operations. A modern CNC lathe machine (Okuma
LH35-N) was used for the tests. It was noted that worn vee profile
tools tended to produce a greater increase in the vertical force
component than the axial component, whereas knife tools tended to
show a more pronounced increase in the axial component.", keywords = "Cutting force, Tool deflection, Turning, Cuttingconditions.", volume = "4", number = "9", pages = "773-6", }