Use of process models

• Analysis of cutting process

• Predict force, power, temperature,
stresses, surafce finish, tolerances etc.
• Compensate errors
• Select optimal process parameters
• Process plan
• Machine and tool selection
Basic Types of Chip Formation
 Process Modeling
Chip Vc Tool
Vc Chip - flow angle
c
Chip

Tool
i

FR

Workpiece Workpiece
Vw
i
FP
90°
Vw FQ
FP

Cutting edge inclination i

FQ
 Review on Modelling
Process
Models

Semi –
Analytical FEM
Analytical

Thin Shear
Mechanistic Slip Line
Zone

CHIP
The secondary
Dual Zone
The primary
shear zone
shear zone
(Rake Face) Model
(Shear Plane) TOOL

WORKPIECE

The third shear

zone (Flank)
Orthogonal Cutting
Primary Shear Zone
(Chip Formation)
Secondary Shear Zone
(Chip-Tool Contact)
Kayma
sürtünmesi

Yapışma


 x
stress distribution

Px   P0 1  
 c 
.
  P
  1 distance from tool tip
Normal Stress Shear Stress
 Third Deformation Zone
(Hone Radius and Clearance)
Basic Definitions
Merchant Circle (Force Circle)
: Shear Angle
: Rake Angle
: Clearance angle
tc
C : Friction Angle=tan-1(F/N)

 TOOL
Ff: Feed (Thrust Force)
 A Fs Ft: Tangnetial (Cutting) Force
t
Ft B 
Fn
Ff
R F


N
 Cutting Forces
R = Fs / [cos (  +   )]
tc Ft=R cos (), Ft=R cos ()
C
Fs = As
 TOOL As=b.t/sin 
 A Fs
t Ft
B 

Fn
Ff
R F
Ft = .b.t cos (   )/ [sin  cos (  +   ]

 Ff = .b.t sin (   /[sin cos (  +   ]

N
Force Prediction in Orthogonal Cutting
Ft = .b.t cos (   )/ [sin  cos (  +   ]
tc
C Ff = .b.t sin (   /[sin cos (  +   ]
 TOOL
 A F
t Ft s

 B  Shear Angle ?

Fn
Ff
R F

 Merchant’s equation:

N Minimization of total cutting energy
Applying d/d = 0 gives:
  45° + /2  /2
 Orthogonal Database
r cos  Kayma açısı
tan   (r=tc/t)
1  r sin 


 F f cos   Ft sin   sin  Akma gerilimi
bt
F f + Ft tan  Sürtünme katsayısı
tan  
Ft  F f tan 
Kt = .cos (   )/ [sin  cos (  +   ]
Kf = .sin (   /[sin cos (  +   ]

Ft = b.t.Kt
Ff = b.t.Kf
 Mechanistic Approach
K
Cutting Force Coefficients
F f  K f bh Kt=KTh
-p
Ft  Kt bh Kr=KRh-q h
Fa  K Abh
Ka=KAh-s
The Third Deformation Zone

F f  K feb + K fcbh
Ft  K teb + K tcbh

Kfe: İlerleme yönündeki kenar kesme kuvvet katsayısı

Kte: Tanjant yöndeki kenar kesme kuvvet katsayısı
Kfc: İlerleme yönündeki kesme kuvvet katsayısı
Ktc: Tanjant yöndeki kesme kuvvet katsayısı
Cutting Force Coefficient Predictions

• Orthogonal Tube Cutting Tests

Experimental Identification of Cutting Force
Coefficients
Work material: Ti6Al4V
 Several Experimental Results
AISI 4340
900 1400

Tangential Force (N)

750 1200
Feed Force (N)

1000
600 800
450 600
300 400 Rake 0°
Rake 0° 200
150 Rake 5°
Rake 5° 0
0
0.05 0.1 0.15 0.2 0.25 0.3
0.05 0.1 0.15 0.2 0.25 0.3 Feed Rate (mm/rev)
Feed Rate (mm/rev)
V=60 m/min

600 1200

Tangential Force (N)

500 1000
Feed Force (N)

400 800
300 600
200 400
Rake 0° Rake 0°
100 Rake 5°
200 Rake 5°
0 0
0.05 0.1 0.15 0.2 0.25 0.3 0.05 0.1 0.15 0.2 0.25 0.3
Feed Rate (mm/rev) Feed Rate (mm/rev)

V=150 m/min
 Several Experimental Results
AISI 4340
700 1000

Tangential Force (N)

600 800
Feed Force (N)

500
400 600
300 400
200
Rake 0° 200 Rake 0°
100
Rake 5° Rake 5°
0 0
0 100 200 300 400 0 100 200 300 400
Cutting Speed (m/min) Cutting Speed (m/min)
f=0.15 mm/rev

800 1250

Tangential Force (N)

1000
Feed Force (N)

600
750
400
500
200 Rake 0° Rake 0°
250
Rake 5° Rake 5°
0 0
0 100 200 300 400 0 100 200 300 400
Cutting Speed (m/min) Cutting Speed (m/min)

f=0.25 mm/rev
Several Experimental Results – Shear Angle
AISI 4340
35 35
30

Shear Angle ( ° )
30
Shear Angle ( ° )

25 25
20 20
15 15
10 Rake 0° 10
Rake 0°
5 Rake 5° 5 Rake 5°
0 0
0.05 0.1 0.15 0.2 0.25 (b) 0.05 0.1 0.15 0.2 0.25
(a) Feed Rate (mm/rev) Feed Rate (mm/rev)

The effect of feed rate on shear angle for different cutting speeds,
a) V=60 m/min b)V=150 m/min
40
35 35

Shear Angle ( ° )
30 30
Shear Angle ( ° )

25 25
20 20
15 15
10 Rake 0° 10 Rake 0°
5 Rake 5° 5 Rake 5°
0 0
0 100 200 300 400 0 100 200 300 400
Cutting Speed (m/min) (b)
Cutting Speed (m/min)
(a)
The effect of cutting speed on shear angle for different feed rates,
a) f=0.15 mm/rev b) f= 0.25 mm/rev
Several Experimental Results – Friction Angle
AISI 4340
35 35
Friction Angle ( ° )

30

Friction Angle ( ° )
30
25 25
20 20
15 15
10 Rake 0° 10
Rake 0°
5 Rake 5° 5 Rake 5°
0 0
0.05 0.1 0.15 0.2 0.25 0.05 0.1 0.15 0.2 0.25
(a) (b)
Feed Rate (mm/rev) Feed Rate (mm/rev)

The effect of feed rate on friction angle for different cutting speeds,
a) V= 150 m/min b) V= 250 m/min
35
Friction Angle ( ° )

30
25
20
15
10
Rake 0°
5
Rake 5°
0
50 100 150 200 250 300 350 400 450
Cutting Speed (m/min)

The effect of cutting speed on friction angle for different rake angles
 Several Experimental Results – Shear
Stress AISI 4340
800 800
Shear Stress (Mpa)

Shear Stress (Mpa)

600 600

400 400

200 200
Rake 0° Rake 5°
0 0
50 100 150 200 250 300 350 400 450 50 100 150 200 250 300 350 400 450
Cutting Speed (m/min) Cutting Speed (m/min)

The effect of cutting speed on shear stress for different rake angles
750
Shear Stress (Mpa)

600
450
300
Rake 0°
150
Rake 5°
0
0.05 0.1 0.15 0.2 0.25 0.3
Feed Rate (mm/rev)

The effect of feed rate on shear stress for different rake angles
 Observations

• Shear angle increases with rake angle

• Friction coeff. İncreases with rake angle
• Forces increase with friction
• Forces decrease as shear angle increases
• Chip thickness decreases with increasing
shear angle
• Shear angle decreases as friction
increases
Orthogonal Database Example
Paramre Denklem
Sürtünme Açısı   20.6 + 0.12
 rc cos  
  tan 1  
 1  rc sin   
Kayma Açısı rc  C0 h C1
C0  0.8477  0.0048
C1  0.2775  0.0047
AISI 4340
Kayma Gerilimi  s  650

Parameter Equation

Friction Angle   19.95

 rc cos  
  tan 1  
 1  rc sin   
Shear Angle rc  C0 h C1
C0  0.9579 + 0.0051
C1  0.2295  0.0041 Ti6Al4V
Shear Stress  s  525
Edge force coeff. at the K te  50 (Clearance 5º)
tangential direction
Edge force coeff. at the K fe  73 (Clearance 5º)
feed direction
 Force Predictions from Database
10
1000
8

% Error
800
Force (N)

6
600

400 4
200 2
0 0
0 0.05 0.1 0.15 0.2 0.25 0.3
0.1 0.15 0.2 0.25
Feed Rate (mm/rev) Feed Rate (mm/rev)

14
1000
12
10

% Error
800
Force (N)

8
600 6
400 4
2
200 0
0 0.1 0.15 0.2 0.25
Feed Rate (mm/rev)
0 0.05 0.1 0.15 0.2 0.25 0.3
Feed Rate (mm/rev)

150 m/min 250 m/min

AISI 4340
 Contact Mechanics at Rake Face

(a) (b) Sliding region Sticking Hone

region

Sliding region Sticking Hone Sliding region Hone

(c) (d)
region

(a) The sliding marks at 500 magnification, and rake face view of the tests at 200 magnification
with feed rate of 0.3 mm/rev and cutting speeds of (b) 100 m/min, (c) 300 m/min, and (d) 600 m/min.
 Temas Uzunlukları
5 4
4.5 3.5

contact length / feed

contact length / feed

4 3
3.5 ℓc
3 ℓc 2.5
2.5 2
2 1.5
1.5 ℓp
1 ℓp
1
0.5 0.5
0 0
0 200 400 600 100 400 700 1000 1300
cutting speed (m/min) cutting speed (m/min)
(a) (b)

The predicted variation of the ratio of the contact length and feed for AISI 1050 steel with
(a) coated carbide and (b) CBN cutting tools
•Kesme hızı arttıkça temas uzunluğu azalıyor
•Kesme hızı arttıkça yapışkan temas (sticking) azalıyor
•Yüksek hızlarda temas sürtünme “sliding” haline geliyor
•Genel olarak yapışkan kısım toplam temasın %15 kadar
•Toplam temas uzunluğu ilerlemenin (t) 3-5 katı kadar
•Yapışkan temas uzunluğu ilerlemenin 0-1.5 katı kadar
 Sliding Friction Coefficient

sticking / sliding friction

1

0.8

coefficient
0.6

0.4

0.2

0
0 0.2 0.4 0.6
sticking / total contact length (mm)

•Yapışkan kısımdaki sürtünme katsayısı daha düşük

•Sürtünme katsayısı yapışkan uzunluk arttıkça azalıyor
•Ölçülen sürtünme katsayısı iki alandaki sürtünme katsayılarının sonucu
 Several Examples – AISI 1050

0.7 0.7
Uncoated

sliding friction coefficient

sliding friction coefficient

0.6 0.6

0.5
Carbide 0.5

0.4 0.4

0.3 0.3

Coated
0.2 non-cutting tests 0.2
non-cutting tests
0.1 cutting tests 0.1
Carbide
cutting tests
0 0
0 200 400 600 800 0 200 400 600 800
friction speed (m/min) friction speed (m/min)

0.7 0.7

sliding friction coefficient

sliding friction coefficient

0.6 0.6

0.5
Ceramic 0.5

0.4 0.4

0.3 0.3

0.2 0.2

0.1
CBN 0.1

0 0
0 200 400 600 800 0 200 400 600 800
friction speed (m/min) friction speed (m/min)
 Several Examples

0.7

sliding friction coefficient

0.6

Uncoated
vs AISI 4340
0.5

Carbide 0.4

0.3

0.2

0.1 non-cutting tests

cutting tests
0
0.7 0 200 400 600 800
friction speed (m/min)
sliding friction coefficient

0.6

0.5

0.4

0.3

0.2 HSS vs Ti6Al4V

0.1

0.0
0 2 4 6 8 10
friction speed (m/min)
 Effect of Friction Model on Cutting
Force Predictions
Shear Stress Distribution
Model on the Rake
  1 x  p
Stick+Slide   P  p  x  c

Only Sliding   P 0  x  c

Only Sticking   1 0  x  c

120 120

Cutting Force Error - %

sticking+sliding only sliding sticking+sliding only sliding
Feed Force Error - %

100 only sticking 100 only sticking

80 80

60 60

40 40

20 20

0 0
76 152 216 304 606 76 152 216 304 606
Cutting Speed - m/min Cutting Speed - m/min
 Orthogonal vs. Oblique Cutting

Chip Vc Tool
Vc Chip - flow angle
c
Chip

Tool
Workpiece i
Vw
FR
FP
Workpiece

FQ

i
90°
Vw FQ
FP

Cutting edge inclination i

 Oblique Cutting
Chip - flow angle Vc
c
Chip
i: inclination angle
D c: chip flow angle
Tool
B
E s: shear flow angle
A i

FR

Workpiece

i
90°
FQ Vw
FP
Cutting edge inclination i
Mechanics of Oblique Cutting 1
Mechanics of Oblique Cutting 2
 Cutting Force Coefficients
 cos(  n   n ) + tan c sin  n tan i  sin(  n   n )
Ktc  ; K rc 
sin n c sin n cos i c

 cos(  n   n ) tan i  tan c sin  n

K ac 
sin n c FA

c  cos2 (n + ln   n ) + tan 2 c sin 2 n

s
Fa

Ft FT
ηc

ℓc

ℓp
1 P0
 Direct Identification of Cutting Force
Coefficients

• From orthogonal tube cutting tests

– Dynamometer
– DAQ Acquisiton Setup
– Orthogonal Cutting Conditions
– Tube Cutting
Prediction of Cutting Forces
Ft  K tcbf + K teb
F f  K fcbf + K feb
Fr  K rcbf + K reb
Effect of Inclination Angle
 Cutting Force Coefficients - Ti6Al4V
i=7o i=11o
800 800

Kfc (N/mm)
600
Kfc (N/mm)

600
400
400
200 Measured Kfc
200 Measured Kfc
Transformed Kfc
Transformed Kfc 0
0 0.06 0.12 0.18
0.06 0.12 0.18
Feed Rate (mm/rev)
Feed Rate (mm/rev) 1800
2100 1500

Ktc (N/mm)
1800 1200
Ktc (N/mm)

1500 900
1200 600
900 Measured Kfc
300
600 Transformed Kfc
Measured Kfc 0
300 Transformed Kfc 0.06 0.12 0.18
0
0.06 0.12 0.18 Feed Rate (mm/rev)

Feed Rate (mm/rev) 200

200
Krc (N/mm) 150
Krc (N/mm)

150
100
100
50 Measured Kfc
50 Measured Kfc Transformed Kfc
Transformed Kfc 0
0 0.06 0.12 0.18
0.06 0.12 0.18
Feed Rate (mm/rev)
Feed Rate (mm/rev)
 Turning
Workpiece

F ,V
tang

Frad

Ffeed

Vf
Chip

Tool
 Turning Process Model
• Oblique cutting model
• 2 new parameters
– Approach angle
– Nose radius
 Turning Forces
Workpiece

F ,V
tang

Frad

Ffeed

Vf
Chip

Tool

Kuvvetler:
1. İlerleme Yönünde
2. Radyal Yönde
3. Kesme Hızı Yönünde
 Approach Angle

Filerleme   F f cos c  + Fa sin c 

Fradyal  F f sin c  + Fa cosc 
Ftan  Ft
 Modeling of Milling


ft

FEED
• Trochoidal motion due to tool rotation and feed motion
• Multiple cutting edges engage and remove chips
• Chip thickness can be approximated by
h=ft sin  where ft=F/Nn
N: number of teeth n:rpm F: feed (mm/min)
 Milling Force Modeling
F
• Predict forces for given conditions
• Cutting models
– Exponential force model h
K

– Linear edge-force model h

F

Fc
Fe
h
 Milling Forces
Exponential Force Model
Differential milling forces

h j ( , z )  f t sin j ( z )
tan 
 j ( z )   + ( j  1) p  z
R
2
z ju ( ) p 
Fx j ( ) 
Kt ft R 
4 tan   
 cos 2 j + K r 2 j ( z )  sin 2 j ( z )  
 z jl ( )
N
N
Fx ( )   Fx j ( )
z ju ( )
Kt ft R 
 
2 j ( z )  sin 2 j ( z ) + K r cos 2 j ( z ) 
j 1
Fy j ( )  
4 tan    z jl ( ) N
Fy ( )   Fy j ( )
j 1
K K fR z ju ( )
Fzj ( )   a t t cos  j ( z ) 
N
Fz ( )   Fz j ( )
tan  z jl ( )
j 1
 Milling Forces
Linear Edge-Force Model
Differential milling forces

h j ( , z )  f t sin j ( z )
tan 
 j ( z )   + ( j  1) p  z
R
2
p 
N
z
  ju
R ft 
 
N
Fxj ( )  K sin  ( z )  K cos  ( z ) + K 2 ( z )  sin 2 ( z )  K cos 2 ( z )  Fx ( )   Fx j ( )
tan   te j re j
4 
rc j j tc j  
 z jl j 1

z N
  ju Fy ( )   Fy ( )
Fxj ( ) 
R
tan 
ft 
  
  K re sin  j ( z )  Kte cos  j ( z ) + 4  K tc 2 j ( z )  sin 2 j ( z )  K rc cos 2 j ( z )  
  z jl j 1
j

N
R z Fz ( )   Fz j ( )
Fxj ( )   K ae j ( z )  ft K ac cos  j ( z )  ju (9)
tan    z jl j 1
 Helical flute-cutting zone intersection

1
lag angle

2 tan 
 j ( z )   + ( j  1) p  z
R


3
0
st ex
6 5
4 j

 w 1 1  w  for up milling
st ( z )    cos1 1   
R   R
for down milling ; ex ( z ) cos
  
a
1


2
Integration Limits
3
0
st 5 ex j
6

Case Condition In/out zjl zju

1 tan  Out NA NA
 j  ex and ( j  a )  ex
R
2 tan  In cut R a
 j  ex and st  ( j  a )  ex ( j  ex )
R tan 

3 tan  In cut R R
 j  ex and ( j  a )  st ( j  ex ) ( j  st )
R tan  tan 

4 tan  In cut 0 a
st   j  ex and st  ( j  a )  ex
R

5 tan  In cut 0 R
st   j  ex and ( j  a )  st ( j  st )
R tan 

6 tan  Out NA NA
 j  st and ( j  a )  ex
R
 Mechanistic modeling of forces
Conduct milling experiments and obtain average milling forces in 3
directions varying w and ft

PFy  QFx Fx Fz
Kr  ; Kt  ; Ka 
PFx + QFy ft ( P  QK r ) ft Kt T
Metninizi buraya girin 1
ex ex ex
[ cos 2 ] ; Q  [ 2  sin 2 ] ; T  [ cos  ]
aN aN aN
P
2 st 2 st 2 st

Kt  KT ha p ; Kr  K R haq ; Ka  K Aha s

cos st  cos st

Average uncut chip thickness ha  ft
ex  st
 Milling Force Simulation
Example
Titanium (Ti6Al4V) database
  613 MPa ,   19.1 + 0.29 
r  r0 h a , r0  1.755  0.028 , a  0.331  0.0082
Kte  24 N/mm , K re  43 N/mm

Ti6Al4V work material

4-flute carbide end mill
19 mm dia., 30 deg. helix
12 deg. rake angle
Half immersion up milling
5 mm axial depth of cut
0.05 mm/tooth feed
30 m/min cutting speed