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Characterization & modeling of chip flow angle & morphology in 2D & 3D turning process
University West, Department of Engineering Science, Research Enviroment Production Technology West. (PTW)ORCID iD: 0000-0003-3877-9067
2015 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Within manufacturing of metallic components, machining plays an important role and is of vital significance to ensure process reliability. From a cutting tool design perspective,  tool macro geometry  design  based on physics based  numerical modelling  is highly needed  that can predict chip morphology.  The chip morphology describes the chip shape geometry and the chip curl geometry. The prediction of chip flow and chip shape is vital in predicting chip breakage, ensuring good chip evacuation and lower surface roughness.  To this end, a platform where such a  numerical model’s chip morphology prediction  can be compared with experimental investigation is needed and is the focus of this work. The studied cutting processes are orthogonal cutting process and nose turning process. Numerical models that simulate the chip formation process are employed to predict the chip morphology and are accompanied by machining experiments. Computed tomography is used  to scan the chips obtained from machining experiments and its ability to capture the variation in  chip morphology  is evaluated.  For nose turning process,  chip  curl parameters during the cutting process are to be calculated. Kharkevich model is utilized in this regard to calculate the  ‘chip in process’ chip curl parameters. High speed videography is used to measure the chip side flow angle during the cutting process experiments and are directly compared to physics based model predictions. The results show that the methodology developed provides  the framework where advances in numerical models can be evaluated reliably from a chip morphology prediction capability view point for nose turning process. The numerical modeling results show that the chip morphology variation for varying cutting conditions is predicted qualitatively. The results of quantitative evaluation of chip morphology prediction shows that the error in prediction is too large to be used for predictive modelling purposes.

Place, publisher, year, edition, pages
Trollhättan: University West , 2015. , 67 p.
Series
Licentiate Thesis: University West, 5
Keyword [en]
Chip curl, Chip flow, Computed tomography, Chip formation, Machining
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-8671ISBN: 978-91-87531-20-0 (print)ISBN: 978-91-87531-21-7 (print)OAI: oai:DiVA.org:hv-8671DiVA: diva2:871453
Presentation
2016-03-31, 11:00 (English)
Supervisors
Available from: 2016-04-01 Created: 2015-11-14 Last updated: 2016-04-01Bibliographically approved
List of papers
1. Characterization of Chip Morphology in Oblique Nose Turning employing High Speed Videography and Computed Tomography Technique
Open this publication in new window or tab >>Characterization of Chip Morphology in Oblique Nose Turning employing High Speed Videography and Computed Tomography Technique
2016 (English)Conference paper, Published paper (Refereed)
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-8669 (URN)
Conference
6th International Conference on Competitive manufacturing – COMA ‘16”in Stellenbosch, South Africa 2016
Note

Ingår i licentiatuppsats

Available from: 2015-11-14 Created: 2015-11-14 Last updated: 2016-02-09Bibliographically approved
2. FE Modelling and Characterization of Chip Curl in Nose Turning process
Open this publication in new window or tab >>FE Modelling and Characterization of Chip Curl in Nose Turning process
(English)In: International Journal of Machining and Machinability of Materials, ISSN 1748-572XArticle in journal (Refereed) Submitted
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-8670 (URN)
Note

Inågr i licentiatuppsats

Available from: 2015-11-14 Created: 2015-11-14 Last updated: 2015-11-14Bibliographically approved
3. Modeling of Chip curl in Orthogonal Turning using Spiral Galaxy describing Function
Open this publication in new window or tab >>Modeling of Chip curl in Orthogonal Turning using Spiral Galaxy describing Function
2016 (English)Conference paper, Published paper (Refereed)
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-8668 (URN)
Conference
“6th International Conference on Competitive Manufacturing – COMA ‘16”in Stellenbosch, South Africa 2016
Note

Ingår i Licentiatuppsats

Available from: 2015-11-14 Created: 2015-11-14 Last updated: 2016-02-09Bibliographically approved
4. Quantitative Characterization of Chip Morphology Using Computed Tomography in Orthogonal Turning Process
Open this publication in new window or tab >>Quantitative Characterization of Chip Morphology Using Computed Tomography in Orthogonal Turning Process
2015 (English)In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 33, 299-304 p.Article in journal (Refereed) Published
Abstract [en]

Abstract The simulation of machining process has been an area of active research for over two decades. To fully incorporate finite element (FE) simulations as a state of art tool design aid, there is a need for higher accuracy methodology. An area of improvement is the prediction of chip shape in FE simulations. Characterization of chip shape is therefore a necessity to validate the FE simulations with experimental investigations. The aim of this paper is to present an investigation where computed tomography (CT) is used for the characterization of the chip shape obtained from 2D orthogonal turning experiments. In this work, the CT method has been used for obtaining the full 3D representation of a machined chip. The CT method is highly advantageous for the complex curled chip shapes besides its ability to capture microscopic features on the chip like lamellae structure and surface roughness. This new methodology aids in the validation of several key parameters representing chip shape. The chip morphology’s 3D representation is obtained with the necessary accuracy which provides the ability to use chip curl as a practical validation tool for FE simulation of chip formation in practical machining operations. The study clearly states the ability of the new CT methodology to be used as a tool for the characterization of chip morphology in chip formation studies and industrial applications.

Keyword
validation, Finite lement method, Computed Tomography
National Category
Materials Engineering
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-7888 (URN)10.1016/j.procir.2015.06.053 (DOI)2-s2.0-84939796397 (Scopus ID)
Conference
9th CIRP Conference on Intelligent Computation in Manufacturing Engineering - CIRP ICME ’14
Available from: 2015-08-13 Created: 2015-08-13 Last updated: 2017-12-04Bibliographically approved

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