Optimization and fabrication of curvilinear micro-grooved cutting tools for sustainable machining based on finite element modelling of the cutting process
The benefits of micro-textures on cutting tools have been confirmed widely in implementing sustainable machining. However, the derivative cutting processes induced by the sharp edges of textures weakened the potential benefits. In our preliminary work, the newly designed curvilinear micro-grooved cu...
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| Published in | International journal of advanced manufacturing technology Vol. 110; no. 5-6; pp. 1327 - 1338 |
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| Main Authors | , , , , |
| Format | Journal Article |
| Language | English |
| Published |
London
Springer London
01.09.2020
Springer Nature B.V |
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| Online Access | Get full text |
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| Abstract | The benefits of micro-textures on cutting tools have been confirmed widely in implementing sustainable machining. However, the derivative cutting processes induced by the sharp edges of textures weakened the potential benefits. In our preliminary work, the newly designed curvilinear micro-grooved cutting tool has been proved to eliminate derivative cutting processes and implement sustainable machining than non-textured tools by three-dimensional (3D) finite element (FE) simulations. In this paper, the curvilinear micro-groove structures were optimized and fabricated to further improve the cutting performance of minimizing specific cutting energy. The results indicated that all the micro-groove parameters, including the width, spacing, depth, and edge distance (the distance from cutting edge to the micro-grooved area), showed obvious influence on specific cutting energy in their own ways. Specific cutting energy of the metal cutting processes can be effectively reduced by the optimal curvilinear micro-grooved cutting tools, although the optimal structures used in rough and finish turning conditions were different. In addition, a new two-step method was developed in this work to prepare curvilinear micro-grooves on carbide tools with femtosecond laser. The optimal curvilinear micro-grooved cutting tools were fabricated and used in cutting experiments, which verified the simulative results. |
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| AbstractList | The benefits of micro-textures on cutting tools have been confirmed widely in implementing sustainable machining. However, the derivative cutting processes induced by the sharp edges of textures weakened the potential benefits. In our preliminary work, the newly designed curvilinear micro-grooved cutting tool has been proved to eliminate derivative cutting processes and implement sustainable machining than non-textured tools by three-dimensional (3D) finite element (FE) simulations. In this paper, the curvilinear micro-groove structures were optimized and fabricated to further improve the cutting performance of minimizing specific cutting energy. The results indicated that all the micro-groove parameters, including the width, spacing, depth, and edge distance (the distance from cutting edge to the micro-grooved area), showed obvious influence on specific cutting energy in their own ways. Specific cutting energy of the metal cutting processes can be effectively reduced by the optimal curvilinear micro-grooved cutting tools, although the optimal structures used in rough and finish turning conditions were different. In addition, a new two-step method was developed in this work to prepare curvilinear micro-grooves on carbide tools with femtosecond laser. The optimal curvilinear micro-grooved cutting tools were fabricated and used in cutting experiments, which verified the simulative results. |
| Author | Sun, Shufeng Li, Jianming Liu, Guoliang Özel, Tuğrul Wang, Dexiang |
| Author_xml | – sequence: 1 givenname: Guoliang surname: Liu fullname: Liu, Guoliang organization: School of Mechanical & Automotive Engineering, Key Lab of Industrial Fluid Energy Conservation and Pollution Control (Ministry of Education), Qingdao University of Technology – sequence: 2 givenname: Tuğrul surname: Özel fullname: Özel, Tuğrul organization: Manufacturing and Automation Research Laboratory, Department of Industrial and Systems Engineering, Rutgers University – sequence: 3 givenname: Jianming surname: Li fullname: Li, Jianming organization: School of Mechanical Engineering, University of Jinan – sequence: 4 givenname: Dexiang surname: Wang fullname: Wang, Dexiang organization: School of Mechanical & Automotive Engineering, Key Lab of Industrial Fluid Energy Conservation and Pollution Control (Ministry of Education), Qingdao University of Technology – sequence: 5 givenname: Shufeng surname: Sun fullname: Sun, Shufeng email: shufeng2001@163.com organization: School of Mechanical & Automotive Engineering, Key Lab of Industrial Fluid Energy Conservation and Pollution Control (Ministry of Education), Qingdao University of Technology |
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| Keywords | Sustainable machining Femtosecond laser processing Curvilinear micro-grooves Specific cutting energy FEM |
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| SubjectTerms | CAE) and Design Carbide tools Computer simulation Computer-Aided Engineering (CAD Cutting energy Cutting tools Engineering Finite element method Grooves Industrial and Production Engineering Mechanical Engineering Media Management Metal cutting Optimization Original Article Turning (machining) |
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| Title | Optimization and fabrication of curvilinear micro-grooved cutting tools for sustainable machining based on finite element modelling of the cutting process |
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