Modeling of the forces and cutting torque developed during drilling opreation is imperative to ac... more Modeling of the forces and cutting torque developed during drilling opreation is imperative to achieve better cutting performance vig. hole geometry, precision, and productivity etc. The present work is an effort to develop an efficient yet simple to apply drill force model considering the three regions of cut present at (i) primary cutting edge (ii) secondary cutting edges and (iii) severe indentation zone present at the chisel edge. A piecewise orthogonal cutting was assumed to analyze drill forces due to material shear at primary and secondary cutting zones. The forces due to cutting at indentation zone were modeled using well established extrusion theory. Chip-tool rubbing at the primary rake surface and at the chisel edge wedge were also considered to estimate the increment in overall cutting forces due to prevailing friction. The instantaneous elemental machining forces from all the three zones along with the frictional force components were summed up in the natural directions of thrust and cutting force, to calculate net thrust along the drill axis and overall cutting force acting tangentially to the drill front body and hence the net torque on the twist drill. The model results were compared and verified with experimental data of a referred work. Individual contributions of the cutting and indentation zones along with tool chip interface friction, towards the vertical thrust and torque, were also analyzed.
Forces in Hard turning can be used to evaluate the performance of the process. Cutting parameters... more Forces in Hard turning can be used to evaluate the performance of the process. Cutting parameters have their own influence on the cutting forces on the tool. The present work is an attempt to develop a force prediction model based on full factorial design of experiments for machining EN31 steel (equivalent to AISI 52100 steel) using uncoated CBN tool. The force and surface roughness regression models were developed using the data from various set of experiments with in the range of parameters selected. The predictions from the models were compared with the measured force and surface roughness values. The ANOVA analysis was undertaken to test the goodness of fit of data.
Modeling of the forces and cutting torque developed during drilling opreation is imperative to ac... more Modeling of the forces and cutting torque developed during drilling opreation is imperative to achieve better cutting performance vig. hole geometry, precision, and productivity etc. The present work is an effort to develop an efficient yet simple to apply drill force model considering the three regions of cut present at (i) primary cutting edge (ii) secondary cutting edges and (iii) severe indentation zone present at the chisel edge. A piecewise orthogonal cutting was assumed to analyze drill forces due to material shear at primary and secondary cutting zones. The forces due to cutting at indentation zone were modeled using well established extrusion theory. Chip-tool rubbing at the primary rake surface and at the chisel edge wedge were also considered to estimate the increment in overall cutting forces due to prevailing friction. The instantaneous elemental machining forces from all the three zones along with the frictional force components were summed up in the natural directions of thrust and cutting force, to calculate net thrust along the drill axis and overall cutting force acting tangentially to the drill front body and hence the net torque on the twist drill. The model results were compared and verified with experimental data of a referred work. Individual contributions of the cutting and indentation zones along with tool chip interface friction, towards the vertical thrust and torque, were also analyzed.
Forces in Hard turning can be used to evaluate the performance of the process. Cutting parameters... more Forces in Hard turning can be used to evaluate the performance of the process. Cutting parameters have their own influence on the cutting forces on the tool. The present work is an attempt to develop a force prediction model based on full factorial design of experiments for machining EN31 steel (equivalent to AISI 52100 steel) using uncoated CBN tool. The force and surface roughness regression models were developed using the data from various set of experiments with in the range of parameters selected. The predictions from the models were compared with the measured force and surface roughness values. The ANOVA analysis was undertaken to test the goodness of fit of data.
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