Shreyes N. Melkote

Effect of cutting edge geometry and workpiece hardness on surface generation in the finish hard turning of AISI 52100 steel

Abstract An experimental investigation was conducted to determine the effects of tool cutting edge geometry and workpiece hardness on the surface roughness and cutting forces in the finish hard turning of AISI 52100 steel. Cubic boron nitride inserts with various representative cutting edge preparations and through-hardened AISI 52100 steel bars were used as the cutting tools and workpiece material, respectively. This study shows that the effect of edge geometry on the surface roughness and cutting forces is statistically significant. Specifically, large edge hones result in higher average surface roughness values than small edge hones, due to increase in the extent of ploughing compared to shearing. The effect of the two-factor interaction of the edge geometry and workpiece hardness on the surface roughness is also found to be important. Additionally, large edge hones result in higher forces in the axial, radial, and tangential directions than small edge hones. It is also shown that the effect of workpiece hardness on the axial and radial components of force is significant, particularly for large edge hones.

Effect of Cutting-Edge Geometry and Workpiece Hardness on Surface Residual Stresses in Finish Hard Turning of AISI 52100 Steel

An experimental investigation was conducted to determine the effects of tool cutting-edge geometry (edge preparation) and workpiece hardness on surface residual stresses for finish hard turning of through-hardened AISI 52100 steel. Polycrystalline cubic boron nitride (PCBN) inserts with representative types of edge geometry including up-sharp edges, edge hones, and chamfers were used as the cutting tools in this study. This study shows that tool edge geometry is highly influential with respect to surface residual stresses, which were measured using x-ray diffraction. In general, compressive surface residual stresses in the axial and circumferential directions were generated by large edge hone tools in longitudinal turning operations. Residual stresses in the axial and circumferential directions generated by large edge hone tools are typically more compressive than stresses produced by small edge hone tools. Microstructural analysis shows that thermally-induced phase transformation effects are present at all feeds and workpiece hardness values with the large edge hone tools, and only at high feeds and hardness values with the small edge hone tools. In general, continuous white layers on the workpiece surface correlate with compressive residual stresses, while over-tempered regions correlate with tensile or compressive residual stresses depending on the workpiece hardness.

Machining fixture layout optimization using the genetic algorithm

Abstract Dimensional and form accuracy of a workpiece are influenced by the fixture layout selected for the machining operation. Hence, optimization of fixture layout is a critical aspect of machining fixture design. This paper presents a fixture layout optimization technique that uses the genetic algorithm (GA) to find the fixture layout that minimizes the deformation of the machined surface due to clamping and machining forces over the entire tool path. The advantages of the GA-based method over previously reported non-linear programming methods for fixture layout optimization are discussed. Two GA-based fixture layout optimization approaches are implemented and compared by applying them to several two-dimensional example problems.

Improved workpiece location accuracy through fixture layout optimization

Abstract Inaccuracies in workpiece location lead to errors in position and orientation of a machined feature on the workpiece. The ability to accurately locate a workpiece in a machining fixture is strongly influenced by rigid body displacements of the workpiece caused by elastic deformation of loaded fixture–workpiece contacts. This paper presents a model for improving workpiece location accuracy in fixturing. A discrete elastic contact model is used to represent each fixture–workpiece contact. Reduction in workpiece locating error due to rigid body displacements is achieved through optimal placement of locators and clamps around the workpiece. The layout optimization model is also shown to improve the overall workpiece deflection and reaction force characteristics.

An Explanation for the Size-Effect in Machining Using Strain Gradient Plasticity

This paper aims to explain the size-effect in the Primary Deformation Zone (PDZ) in machining using strain gradient plasticity theory. Considering a parallel-sided shear zone configuration, models are formulated for the evaluation of strain gradient, density of geometrically necessary dislocations, shear strength and the specific shear energy. The analysis of deformation in the PDZ shows that the length of the shear plane represents the fundamental material length scale governing the size-effect. It also provides an estimate of the lower bound on the size-effect observed in the specific shear energy. The general trends predicted by the model are shown to agree well with the experimental values obtained from the literature.

Iterative Fixture Layout and Clamping Force Optimization Using the Genetic Algorithm

Fixture design is a critical step in machining. An important aspect of fixture design is the optimization of the fixture, the primary objective being the minimization of workpiece deflection by suitably varying the layout of fixture elements and the clamping forces. Previous methods for fixture design optimization have treated fixture layout and clamping force optimization independently and/or used nonlinear programming methods that yield sub-optimal solutions. This paper deals with application of the genetic algorithm (GA) for fixture layout and clamping force optimization for a compliant workpiece. An iterative algorithm that minimizes the workpiece elastic deformation for the entire cutting process by alternatively varying the fixture layout and clamping force is proposed. It is shown via an example of milling fixture design that this algorithm yields a design that is superior to the result obtained from either fixture layout or clamping force optimization alone.

Material Strengthening Mechanisms and Their Contribution to Size Effect in Micro-Cutting

The specific cutting energy in machining is known to increase nonlinearly with decrease in uncut chip thickness. It has been reported in the literature that this phenomenon is dependent on several factors such as material strengthening, ploughing due to finite edge radius, and material separation effects. This paper examines the material strengthening effect where the material strength increases nonlinearly as the uncut chip thickness is reduced to a few microns. This increase in strength has been attributed in the past to various factors such as strain rate, strain gradient, and temperature effects. Given that the increase in material strength can occur due to many factors, it is important to understand the contributions of each factor to the increase in specific cutting energy and the conditions under which they are dominant. This paper analyzes two material strengthening factors, (i) the contribution of the decrease in the secondary deformation zone cutting temperature and (ii) strain gradient strengthening, and their relative contributions to the increase in specific cutting energy as the uncut chip thickness is reduced. Finite element (FE)-based orthogonal cutting simulations are performed with Aluminum 5083-H116, a work material with a small strain rate hardening exponent, thus minimizing strain rate effects. Suitable cutting conditions are identified under which the temperature and strain gradient effects are dominant. Orthogonal cutting experiments are used to validate the model in terms of cutting forces. The simulation results are then analyzed to identify the contributions of the material strengthening factors to the size effect in specific cutting energy.

Effect of Tool Edge Geometry on Workpiece Subsurface Deformation and Through-Thickness Residual Stresses for Hard Turning of AISI 52100 Steel

Abstract An experimental investigation was conducted to determine the effect of tool cutting edge geometry on workpiece subsurface deformation and through-thickness residual stresses for finish hard turning of through-hardened AISI 52100 steel. Polycrystalline cubic boron nitride (PCBN) inserts with “up-sharp” edges, edge hones, and chamfers were used as the cutting tools in this study. Examination of the workpiece microstructure reveals that large edge hone tools produce substantial subsurface plastic flow. Flow is not observed when turning with small edge hone tools or chamfered tools, and the workpiece microstructure appears random for these cases. Examination of through-thickness residual stresses shows that large edge hone tools produce deeper, more compressive residual stresses than are produced by small edge hone tools or chamfered tools. Explanations for these effects are offered based on assumed contact conditions between the tool and workpiece.

An Elastic Contact Model for the Prediction of Workpiece-Fixture Contact Forces in Clamping

The design and evaluation of machining fixture performance requires accurate knowledge of workpiece-fixture contact forces since they strongly impact workpiece accuracy during clamping and machining. This paper presents an elastic contact model for the prediction of workpiece-fixture contact forces due to clamping. The fixture and workpiece are considered to be elastic bodies in the vicinity of the contact region. The model is formulated as a constrained quadratic program by applying the principle of minimum total complementary energy. The model predicts the normal force, and the magnitude and direction of the tangential (friction) force at each workpiece-fixture contact due to clamping forces. Experimental verification of the model under different clamping loads shows good agreement between predicted and measured normal and tangential contact forces. The model can be used to analyze fixture performance in terms of the contact forces and contact region deformation.

Statistical Adjustments to Engineering Models

Statistical models are commonly used in quality-improvement studies. However, such models tend to perform poorly when predictions are made away from the observed data points. On the other hand, engineering models derived using the underlying physics of the process do not always match satisfactorily with reality. This article proposes engineering—statistical models that overcome the disadvantages of engineering models and statistical models. The engineering—statistical model is obtained through some adjustments to the engineering model using experimental data. The adjustments are done in a sequential way and are based on empirical Bayes methods. We also develop approximate frequentist procedures for adjustments that are computationally much easier to implement. The usefulness of the methodology is illustrated using a problem of predicting surface roughness in a microcutting process and the optimization of a spot-welding process.