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Harmonic-based-on analysis to discriminate different mechanical actions involved in the machining of hard-to-cut materials.

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Title: Harmonic-based-on analysis to discriminate different mechanical actions involved in the machining of hard-to-cut materials.
Authors: García-Martínez, Enrique1,2 (AUTHOR) Enrique.GMartinez@uclm.es, Molina-Yagüe, Alberto2 (AUTHOR), Miguel, Valentín1,2 (AUTHOR), Martínez-Martínez, Alberto1 (AUTHOR)
Source: International Journal of Advanced Manufacturing Technology. Jul2024, Vol. 133 Issue 1/2, p335-349. 15p.
Subjects: Titanium aluminides, Process control systems, Cutting force, Rapid tooling, Harmonic analysis (Mathematics), Milling cutters, Fast Fourier transforms
Abstract: Cutting force monitoring may be established as a functional control system for machining processes, helping determine the optimal time for tool change since a relationship between tool wear and milling forces exists. However, these forces result from various effect, including chip removal, friction, and vibrations. Predicting the end of functional tool life becomes challenging due to these complex interactions. In this study, it is proposed a decomposed action methodology based on force analysis using the fast Fourier transform and harmonic analysis. In pursuit of a comprehensive understanding of cutting forces during milling process, it is proposed a methodology to capture the signal given by a rotary dynamometer in selective cutting tests directed to discriminate and isolate external friction and other effects. The methodology has been tuned for slot milling of Ti48Al2Cr2Nb titanium aluminide using a single uncoated tungsten carbide insert, under different combinations of depth of cut and feed per tooth, for a fixed cutting speed value. The friction force in the tool flank zone has been demonstrated as the main action due to the small chip section removed, which leads to explain the rapid tool wear in titanium aluminides machining. Friction coefficients ranging from 0.412 to 0.579 have been found in real cutting conditions. This methodology will allow the evaluation of different tool geometries to reduce tool-workpiece friction and wear phenomena, enhancing the tool life. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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DbLabel: Engineering Source
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  Data: Harmonic-based-on analysis to discriminate different mechanical actions involved in the machining of hard-to-cut materials.
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  Data: <searchLink fieldCode="DE" term="%22Titanium+aluminides%22">Titanium aluminides</searchLink><br /><searchLink fieldCode="DE" term="%22Process+control+systems%22">Process control systems</searchLink><br /><searchLink fieldCode="DE" term="%22Cutting+force%22">Cutting force</searchLink><br /><searchLink fieldCode="DE" term="%22Rapid+tooling%22">Rapid tooling</searchLink><br /><searchLink fieldCode="DE" term="%22Harmonic+analysis+%28Mathematics%29%22">Harmonic analysis (Mathematics)</searchLink><br /><searchLink fieldCode="DE" term="%22Milling+cutters%22">Milling cutters</searchLink><br /><searchLink fieldCode="DE" term="%22Fast+Fourier+transforms%22">Fast Fourier transforms</searchLink>
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  Data: Cutting force monitoring may be established as a functional control system for machining processes, helping determine the optimal time for tool change since a relationship between tool wear and milling forces exists. However, these forces result from various effect, including chip removal, friction, and vibrations. Predicting the end of functional tool life becomes challenging due to these complex interactions. In this study, it is proposed a decomposed action methodology based on force analysis using the fast Fourier transform and harmonic analysis. In pursuit of a comprehensive understanding of cutting forces during milling process, it is proposed a methodology to capture the signal given by a rotary dynamometer in selective cutting tests directed to discriminate and isolate external friction and other effects. The methodology has been tuned for slot milling of Ti48Al2Cr2Nb titanium aluminide using a single uncoated tungsten carbide insert, under different combinations of depth of cut and feed per tooth, for a fixed cutting speed value. The friction force in the tool flank zone has been demonstrated as the main action due to the small chip section removed, which leads to explain the rapid tool wear in titanium aluminides machining. Friction coefficients ranging from 0.412 to 0.579 have been found in real cutting conditions. This methodology will allow the evaluation of different tool geometries to reduce tool-workpiece friction and wear phenomena, enhancing the tool life. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
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  Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1007/s00170-024-13773-8
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      – Code: eng
        Text: English
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        PageCount: 15
        StartPage: 335
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      – SubjectFull: Titanium aluminides
        Type: general
      – SubjectFull: Process control systems
        Type: general
      – SubjectFull: Cutting force
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      – SubjectFull: Rapid tooling
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      – SubjectFull: Harmonic analysis (Mathematics)
        Type: general
      – SubjectFull: Milling cutters
        Type: general
      – SubjectFull: Fast Fourier transforms
        Type: general
    Titles:
      – TitleFull: Harmonic-based-on analysis to discriminate different mechanical actions involved in the machining of hard-to-cut materials.
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          Name:
            NameFull: García-Martínez, Enrique
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            NameFull: Molina-Yagüe, Alberto
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            NameFull: Miguel, Valentín
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            NameFull: Martínez-Martínez, Alberto
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          Dates:
            – D: 01
              M: 07
              Text: Jul2024
              Type: published
              Y: 2024
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              Value: 133
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            – TitleFull: International Journal of Advanced Manufacturing Technology
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