Prediction of cutting force in ultra-precision machining of nonferrous metals based on strain energy

The effects of the nonuniform cutting force and elastic recovery of processed materials in ultra-precision machining are too complex to be treated using traditional cutting theories, and it is necessary to take account of factors such as size effects, the undeformed cutting thickness, the tool blunt...

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Autores principales:	Ying Wang, Zewei Yuan, Tianzheng Wu, Heran Yan
Formato:	article
Lenguaje:	EN
Publicado:	AIP Publishing LLC 2021
Materias:	Technology T Engineering (General). Civil engineering (General) TA1-2040
Acceso en línea:	https://doaj.org/article/d85f2b79314241338fa60e7281a92bbd
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spelling	oai:doaj.org-article:d85f2b79314241338fa60e7281a92bbd2021-12-01T18:51:51ZPrediction of cutting force in ultra-precision machining of nonferrous metals based on strain energy2589-554010.1063/10.0005648https://doaj.org/article/d85f2b79314241338fa60e7281a92bbd2021-12-01T00:00:00Zhttp://dx.doi.org/10.1063/10.0005648https://doaj.org/toc/2589-5540The effects of the nonuniform cutting force and elastic recovery of processed materials in ultra-precision machining are too complex to be treated using traditional cutting theories, and it is necessary to take account of factors such as size effects, the undeformed cutting thickness, the tool blunt radius, and the tool rake angle. Therefore, this paper proposes a new theoretical calculation model for accurately predicting the cutting force in ultra-precision machining, taking account of such factors. The model is first used to analyze the material deformation of the workpiece and the cutting force distribution along the cutting edge of a diamond tool. The size of the strain zone in different cutting deformation zones is then determined by using the distribution of strain work per unit volume and considering the characteristics of the stress distribution in these different deformation zones. Finally, the cutting force during ultra-precision machining is predicted precisely by calculating the material strain energy in different zones. A finite element analysis and experimental data on ultra-precision cutting of copper and aluminum are used to verify the predictions of the theoretical model. The results show that the error in the cutting force between the calculation results and predictions of the model is less than 14%. The effects of the rake face stress distribution of the diamond tool, the close contact zone, and material elastic recovery can be fully taken into account by the theoretical model. Thus, the proposed theoretical calculation method can effectively predict the cutting force in ultra-precision machining.Ying WangZewei YuanTianzheng WuHeran YanAIP Publishing LLCarticleTechnologyTEngineering (General). Civil engineering (General)TA1-2040ENNanotechnology and Precision Engineering, Vol 4, Iss 4, Pp 043001-043001-11 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	Technology T Engineering (General). Civil engineering (General) TA1-2040
spellingShingle	Technology T Engineering (General). Civil engineering (General) TA1-2040 Ying Wang Zewei Yuan Tianzheng Wu Heran Yan Prediction of cutting force in ultra-precision machining of nonferrous metals based on strain energy
description	The effects of the nonuniform cutting force and elastic recovery of processed materials in ultra-precision machining are too complex to be treated using traditional cutting theories, and it is necessary to take account of factors such as size effects, the undeformed cutting thickness, the tool blunt radius, and the tool rake angle. Therefore, this paper proposes a new theoretical calculation model for accurately predicting the cutting force in ultra-precision machining, taking account of such factors. The model is first used to analyze the material deformation of the workpiece and the cutting force distribution along the cutting edge of a diamond tool. The size of the strain zone in different cutting deformation zones is then determined by using the distribution of strain work per unit volume and considering the characteristics of the stress distribution in these different deformation zones. Finally, the cutting force during ultra-precision machining is predicted precisely by calculating the material strain energy in different zones. A finite element analysis and experimental data on ultra-precision cutting of copper and aluminum are used to verify the predictions of the theoretical model. The results show that the error in the cutting force between the calculation results and predictions of the model is less than 14%. The effects of the rake face stress distribution of the diamond tool, the close contact zone, and material elastic recovery can be fully taken into account by the theoretical model. Thus, the proposed theoretical calculation method can effectively predict the cutting force in ultra-precision machining.
format	article
author	Ying Wang Zewei Yuan Tianzheng Wu Heran Yan
author_facet	Ying Wang Zewei Yuan Tianzheng Wu Heran Yan
author_sort	Ying Wang
title	Prediction of cutting force in ultra-precision machining of nonferrous metals based on strain energy
title_short	Prediction of cutting force in ultra-precision machining of nonferrous metals based on strain energy
title_full	Prediction of cutting force in ultra-precision machining of nonferrous metals based on strain energy
title_fullStr	Prediction of cutting force in ultra-precision machining of nonferrous metals based on strain energy
title_full_unstemmed	Prediction of cutting force in ultra-precision machining of nonferrous metals based on strain energy
title_sort	prediction of cutting force in ultra-precision machining of nonferrous metals based on strain energy
publisher	AIP Publishing LLC
publishDate	2021
url	https://doaj.org/article/d85f2b79314241338fa60e7281a92bbd
work_keys_str_mv	AT yingwang predictionofcuttingforceinultraprecisionmachiningofnonferrousmetalsbasedonstrainenergy AT zeweiyuan predictionofcuttingforceinultraprecisionmachiningofnonferrousmetalsbasedonstrainenergy AT tianzhengwu predictionofcuttingforceinultraprecisionmachiningofnonferrousmetalsbasedonstrainenergy AT heranyan predictionofcuttingforceinultraprecisionmachiningofnonferrousmetalsbasedonstrainenergy
_version_	1718404723836452864

Prediction of cutting force in ultra-precision machining of nonferrous metals based on strain energy

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