- Email: [email protected]
Validation of the slip-line model for serrated chip formation in orthogonal turning under dry and MQL conditions
ScienceDirect Procedia CIRP 00 (2019) 000–000 ScienceDirect Available online atonline www.sciencedirect.com Available at www.sciencedirect.com Available online at www.sciencedirect.com
Procedia CIRP 00 (2019) 000–000
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www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia
Procedia CIRP 00 (2017) 000–000 Procedia CIRP 82 (2019) 124–129 www.elsevier.com/locate/procedia
17th CIRP Conference on Modelling of Machining Operations
17th CIRP Conference on Modelling of Machining Operations Validation of the slip-line model for serrated chip formation in orthogonal turning under dry MQL conditions Validation of the28th slip-line model forand serrated chip formation in orthogonal CIRP Design Conference, May 2018, Nantes, France turning under drya,b,and MQL conditions a Alper Uysal *, I.S. Jawahir A new methodology to analyze the functional and physical architecture of a University of Kentucky, Department of Mechanical Engineering and Institute for Sustainable Manufacturing (ISM), Lexington KY 40506, USA Alper Uysala,b, *, I.S. Jawahir existing products for an assembly oriented product family identification Yildiz Technical University, Department of Mechanical Engineering, Istanbul 34349, Turkey a
b
University of Kentucky, Department of Mechanical Engineering and Institute for Sustainable Manufacturing (ISM), Lexington KY 40506, USA * Corresponding author. Tel.: +90-212-383-2807 ; fax: +90-212-383-3024. E-mail address: [email protected] b Yildiz Technical University, Department of Mechanical Engineering, Istanbul 34349, Turkey a
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
* Corresponding Tel.:Supérieure +90-212-383-2807 fax: +90-212-383-3024. E-mail address: Écoleauthor. Nationale d’Arts et ;Métiers, Arts et Métiers ParisTech, [email protected] EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
Abstract
* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: [email protected]
In this study, the previously developed slip-line model for serrated chip formation was validated in orthogonal turning under dry and MQL Abstract (Minimum Quantity Lubrication) conditions. Face turning experiments were conducted on grooved AISI 304 austenitic stainless steel workpiece with tool inserts cutting edge radius of 50model μm. The andvalidated the maximum and minimum thicknesses were In this study, thehaving previously developed slip-line for cutting serratedforce chip components formation was in orthogonal turningchip under dry and MQL measured validate Lubrication) the model. Inconditions. dry cutting,Face the average prediction errors 9.44%, 4.78% and 7.69% for cutting, thrust, and resultant forces, Abstract (MinimumtoQuantity turning experiments wereare conducted on grooved AISI 304 austenitic stainless steel workpiece respectively. In machining with edge MQL,radius the average prediction errorsforce are 10.79%, 11.49% and maximum 2.46% forand cutting, thrust,chip andthicknesses resultant forces, with tool inserts having cutting of 50 μm. The cutting components and the minimum were respectively. In addition, the average prediction errors forproduct maximum and minimum chip4.78% thicknesses are determined 6.38% 9.12% in dry Inmeasured today’s business environment, towards more variety and isand unbroken. Due to thisas development, the need of to validate the model. Inthe drytrend cutting, the average prediction errors arecustomization 9.44%, 7.69% for cutting, thrust, andand resultant forces, cutting 7.79% and 4.35% in MQL, respectively. respectively. In machining with MQL, the average errors are 10.79%, and 2.46% for cutting, thrust, resultant forces, agile andand reconfigurable production systems emergedprediction to cope with various products11.49% and product families. To design and and optimize production respectively. In as addition, the average prediction for maximum and minimum chip are determined as 6.38% 9.12%aim in dry systems as well to choose the optimal producterrors matches, product analysis methods arethicknesses needed. Indeed, most of the knownand methods to © 2019aand The Authors. Published by Elsevier B.V. cutting 7.79% 4.35% in family MQL, respectively. analyze product orand one product on the physical level. Different product families, however, may differ largely in terms of the number and Peer-review under responsibility of Elsevier the scientific committee of The and 17thchoice CIRP Conference on Modelling of Machining Operations, nature ofThe components. This fact by impedes anB.V. efficient comparison of appropriate product family combinations for the production © 2019 Authors. Published in the person of the Conference Chair Dr Erdem Ozturk and Co-chairs Dr Tom Mcleay and Dr Rachid Msaoubi. © 2019 The Authors. Published by Elsevier B.V. system. A newunder methodology is proposed analyze existing products viewCIRP of their functionalonand physical architecture. aim is to cluster Peer-review responsibility of thetoscientific committee of Thein17th Conference Modelling of MachiningThe Operations Peer-review responsibility of the scientific committee of The 17th CIRPofConference on Modelling of the Machining these productsunder in new assembly oriented product families for the optimization existing assembly lines and creationOperations, of future reconfigurable Keywords: Modelling; turning; chip; lubrication in the person of theBased Conference Chair Dr Erdem and Co-chairs Tom Mcleayisand Dr Rachid Msaoubi. assembly systems. on Datum Flow Chain, Ozturk the physical structure Dr of the products analyzed. Functional subassemblies are identified, and a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the Keywords:between Modelling; turning;families chip; lubrication similarity product by providing design support to both, production system planners and product designers. An illustrative example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of 1. Introduction modelof to back-flow angle by utilizing the thyssenkrupp Presta France is then carried out to give a first industrial evaluation the predict proposed chip approach. previously developed universal slip-line model [5]. © 2017 The Authors. Published by Elsevier B.V. 1. Introduction model to predict chip back-flow angle by utilizing the In literature, there are several slip-line models to understand Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018. Nomenclature
previously developed universal slip-line model [5]. ap undeformed chip thickness Nomenclature and the mechanics metal operations. early BUE built-up edge line analyze models were developedofwith thiscutting assumption [1-9]. In Among undeformed chip thickness ak p studies,studies, the cutting tool[1] waspresented considereda asslip-line sharp, and the slipmaterial shear flow stress these Kudo model for built-uplength edge line models with were adeveloped assumption Among lBUE cutting machining built-up with edgethis (BUE). Maity [1-9]. and Das [2] 1.these Introduction and manufactured and/or k the product materialrange shear flowcharacteristics stress studies, Kudomodel [1] presented a slip-line modelstepfor of MQL minimum quantity lubrication developed a slip-line for machining with a parallel assembled in this system. In this context, the main challenge in lA cutting length machining with a built-up edge (BUE). and [3] Das and [2] P hydrostatic pressure at Point A type chip breaker, and investigated the Maity chip curl Due to the fast development in the domain of modelling and analysis is now not only to cope with single quantity developedCoulomb a slip-line modelatforthe machining a parallel steprMQL minimum cutting edge radius lubrication assumed friction chip-toolwith interface [4]. Fang communication and an ongoing trend of digitization and products, a limited product range or existing product families, hydrostatic pressure at Point A type chipintroduced breaker, aand investigated chip involving curl [3] chip and tP1A uncut chip thickness et al. [5] universal slip-linethemodel digitalization, manufacturing enterprises are facing important but also to be able to analyze and to compare products to define r assumed Coulomb friction at the chip-tool [4]. Fang V cutting edge speedradius curl and chip back-flow in machining with ainterface restricted contact challenges in today’s market environments: a continuing new product families. It can be observed that classical existing uncut chip t1 et al. and [5] introduced universal slip-line model involving w width of cutthickness tool, this modelawas validated by Fang and Jawahir chip [6]. tendency towards reduction of product development times and product families are regrouped in function of clients or features. cutting speed curl and back-flow in machining restricted contact γV1 rake angle Fang [7, chip 8] presented a slip-line modelwith for asharp cutting tools shortened lifecycles. In addition, thereand is and anJawahir increasing assembly orientedshear product families width of cut tool,predict and product this wasforces, validated Fang [6]. However, τw1 tool-chip frictional stress on theare toolhardly edge to SEfind. to themodel cutting chipbythickness tool-chip demand of customization, being at the same time in a global On the product family level, products differ mainly in two rake anglefrictional shear stress on the tool edge SB Fang [7,length. 8] presented a slip-line for sharp an cutting tools τγ21 tool-chip contact Fang and Jawahirmodel [9] proposed analytical competition with competitors all over the world. This trend, main characteristics: (i) the number of components and (ii) edge face SE the τ1rake tool-chip frictional shear stress on the tool rake to predict the cutting forces, chip thickness and tool-chip which is inducing the development from macro to micro type of components (e.g. mechanical, electrical, electronical). tool-chip frictional shear stress on the tool edge SB τ2 contact length. Fang and Jawahir [9] proposed an analytical markets, results in diminished lot sizes due to augmenting Classical methodologies considering mainly single tool-chip frictional shear stress on the tool rakeproducts face τrake product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the 2212-8271 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific of The 17th CIRP on Modelling Machininglevel Operations, in the person of the To cope with this augmenting variety as committee well as to be able to Conference product structure on of a physical (components level) which Conference Erdem Ozturk and Co-chairs Dr B.V. Tom and Dr Rachid Msaoubi.difficulties regarding an efficient definition and 2212-8271 possible ©Chair 2019Dr The Authors. Published by Elsevier identify optimization potentials in Mcleay the existing causes Peer-review under responsibility of the scientific The 17th CIRP Conference on Modelling of Machining Operations, in theAddressing person of the this production system, it is important to havecommittee a preciseofknowledge comparison of different product families. and analyze the mechanics of metal cutting operations. In early
In literature, there aremethod; several slip-line understand Keywords: Assembly; Design Family identification studies, the cutting tool was considered asmodels sharp,toand the slip-
Conference Chair Dr Erdem Ozturk and Co-chairs Dr Tom Mcleay and Dr Rachid Msaoubi. 2212-8271 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the by scientific of The 17th CIRP Conference on Modelling of Machining Operations 2212-8271 © 2017 The Authors. Published Elseviercommittee B.V. 10.1016/j.procir.2019.04.006 Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
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Alper Uysal et al. / Procedia CIRP 82 (2019) 124–129 Author name / Procedia CIRP 00 (2019) 000–000
Several slip-line models were presented subsequently for machining with rounded-edge cutting tools [10-16], and these models are more suitable for practice because of the inherent nature of the roundness of the cutting tools. Fang [10, 11] presented a slip-line model for rounded edge cutting tools and performed quantitative analyses to predict the cutting forces, chip thickness, tool-chip contact length and chip up-curl radius. Wang and Jawahir [12] developed a slip-line model for restricted contact grooved tools having a finite cutting edge radius to predict the cutting forces, chip thickness, chip up-curl radius, temperatures and flow stresses at the primary shear zone and at the tool-chip interface. Jin and Altintas [13] introduced and experimentally validated a slip-line model considering the stress variation in the material deformation region because of the cutting edge radius. Ozturk and Altan [14] proposed a slipline model for rounded edge tools and this model involved a dead metal zone on the rake face. Uysal and Altan [15,16] presented slip-line models for rounded edge [15] and worn rounded edge [16] cutting tools by assuming the existence of dead metal zone and experimentally validated these models. In these studies, the chip formation was considered as continuous. However, serrated chip formation occurs in machining of various materials such as stainless steels, titanium and nickelbased alloys, etc. These materials are generally considered as hard-to-machine materials. Early work by Manyindo and Oxley [17] presented a slip-line model for serrated chip formation in machining of stainless steel with a sharp cutting tool. More recently, Uysal and Jawahir [18] developed a slip-line model for serrated chip formation in machining with a rounded cutting edge. This slip-line model and its associated hodograph are given in Fig. 1. In machining of hard-to-machine materials, flood cooling by applying emulsion-based fluids is a common practice. But, these fluids consist of oils, water, and/or some additives. These chemicals adversely affect the environment and also employees [18, 19]. Therefore, environmental and societal concerns have required more sustainable machining operations. MQL (Minimum Quantity Lubrication) method has been developed as an alternative to flood cooling. In recent years, numerous studies on the usage of MQL in the machining of hard-tomachine materials have been performed [20-26]. Therefore, in this study, the slip-line model for serrated chip formation (Fig. 1), which was previously developed by the authors [18], was experimentally validated for machining under dry and MQL conditions for AISI 304 austenitic stainless steel.
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a Kennametal® Inc. CTCPN-544 tool holder with a rake angle of 3°. The cutting edge radius of the inserts was 50 μm. A new cutting edge was used for every cut to avoid the tool-wear effect.
Fig. 1. (a) Previously developed slip-line model for serrated chip formation, and (b) its hodograph [18].
2. Experimental studies To validate the developed slip-line model for machining under dry and MQL conditions, orthogonal turning experiments were conducted. The studied workpiece material was grooved AISI 304 austenitic stainless steel workpiece shown in Fig. 2. This workpiece material is very similar to AISI 321 workpiece material used in our previous work [18]. Face turning experiments were conducted on a HAAS TL-2 CNC lathe. The experimental set-up is shown in Fig. 3. All experiments were performed with Kennametal® Inc. TPGN220408 uncoated cemented carbide inserts mounted on
Fig. 2. Dimensions of AISI 304 austenitic stainless steel workpiece.
The cutting parameters were selected based on the manufacturer’s recommendations and the state-of-the-art review of literature for machining AISI 304 austenitic stainless steel, and these conditions are shown in Table 1. In MQL method, Coolube 2210EP metalworking lubricant was applied through a UNIST MQL system to the rake face at a 25 ml/h flow rate with 0.4 MPa of air pressure.
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3
3. Validation of the slip-line model with experimental results The previously developed slip-line model was validated using the conducted experimental results under dry and MQL conditions. Figs. 4-7 show the predicted and the average experimental cutting and thrust force components, resultant force, and maximum and minimum chip thickness values.
Fig. 3. Experimental set-up. Table 1. Cutting parameters used in machining of AISI 304 austenitic stainless steel. Cutting environment
Cutting speed, V (m/min)
Undeformed chip thickness, ap (mm)
Rake angle, γ1 (°)
Width of cut, w (mm)
Cutting length, l (mm)
Dry
60
0.1
3
3
10
Dry
80
0.1
3
3
10
Dry
100
0.1
3
3
10
60
0.1
3
3
10
80
0.1
3
3
10
100
0.1
3
3
10
MQL (rake face) MQL (rake face) MQL (rake face)
The cutting force components were measured by a Kistler 9121 3-component tool dynamometer during the experiments. After conducting the orthogonal machining tests, the maximum and minimum chip thicknesses were measured by Keyence VHX digital microscope having VH-Z250R real zoom lens. For this reason, the chip samples were mounted on epoxy, and metallurgically prepared by grinding and polishing processes using Buehler AutometTM 250 automatic grinder/polishing machine. In the metallurgical preparing process, the mounted samples were ground/polished by SiC sandpaper (#240) at 180 rpm with water and then by diamond paper (30 μm) at 180 rpm with water for 4 mins. For polishing, 9 μm diamond suspension was used at 180 rpm for 4 minutes, 6 μm diamond suspension was used at 180 rpm for 3 minutes, 3 μm diamond suspension was used at 180 rpm for 2 minutes and 1 μm and 0.05 μm Alumina suspensions were used at 150 rpm for 2 minutes, respectively. Average values of cutting force components and chip thickness were determined and recorded for all measured results from 3-4 measurements for each datapoint.
Fig. 4. Experimental and predicted cutting force components and the thrust force with varying cutting speed in dry cutting (γ 1= 3°, r = 50 μm, t 1= 0.1 mm, w = 3 mm, PA/k = 0.9, τ1/k = 0.7, τ2/k = 0.7, τrake/k = 0.9) (a) cutting force, (b) thrust force, (c) resultant force.
In dry cutting, the average prediction errors are 9.44%, 4.78% and 7.69% for cutting force, thrust force and resultant force, respectively (Fig. 4). For machining with MQL, the average prediction errors are 10.79%, 11.49% and 2.46% for cutting force, thrust force and resultant force, respectively (Fig. 5). The results show that the force predictions, using the proposed predictive model, are acceptable. Additionally, lower cutting forces are observed in MQL method than for dry cutting and the cutting forces decreased with increase in cutting speed as expected.
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Fig. 6. Experimental and predicted maximum and minimum chip thicknesses according to cutting speed in dry cutting (γ 1= 3°, r = 50 μm, t1 = 0.1 mm, w = 3 mm, PA/k = 0.9, τ1/k = 0.7, τ2/k = 0.7, τrake/k = 0.9) (a) maximum chip thickness, (b) minimum chip thickness.
Fig. 5. Experimental and predicted cutting force components and the thrust force with varying cutting speed in machining with MQL (γ1 = 3°, r = 50 μm, t1 = 0.1 mm, w = 3 mm, PA/k = 0.9, τ1/k = 0.6, τ2/k = 0.56, τrake/k = 0.72) (a) cutting force, (b) thrust force, (c) resultant force.
The average prediction errors for maximum and minimum chip thicknesses are determined as 6.38% and 9.12% in dry cutting (Fig. 6) and 7.79% and 4.35% in machining with MQL (Fig. 7), respectively. From these results, it can be said that the proposed slip-line model can make a good prediction of chip thickness in machining under dry and MQL conditions. Besides, the chip formation in dry cutting and MQL method can be seen in Fig. 8. The presence of tribo-layer in between chip-tool interface, ball bearing effect and mending effect might minimize the frictional force which reduces the chip thickening phenomenon under MQL application. Therefore, the saw-tooth formation can be seen clearly in MQL condition. In Fig. 9, it can be seen that the variation of tool-chip frictional shear stresses around the tool edge and at rake face (Fig. 10) with dry machining and machining with MQL. The results show that an effective lubrication caused a decrease in tool-chip frictional shear stresses, and this may be the reason for the reduction in cutting force values during machining with MQL.
Fig. 7. Experimental and predicted maximum and minimum chip thickness values for varying cutting speed in machining with MQL (γ 1= 3°, r = 50 μm, t1 = 0.1 mm, w = 3 mm, PA/k = 0.9, τ1/k = 0.6, τ2/k = 0.56, τrake/k = 0.72) (a) maximum chip thickness, (b) minimum chip thickness.
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thickness values. Based on the validation of the proposed slipline model, a good correlation was obtained between experimental and predicted results for machining under dry and MQL environments. In addition, it was observed from the solution of the model that an effective lubrication caused a decrease in tool-chip frictional shear stresses. In both conditions, the cutting force components decreased with increasing cutting speed and lower cutting force components were obtained under MQL condition. Besides, the saw-tooth chip formation was observed clearly in machining with MQL due to the presence of tribo-layer at the chip-tool interface. Acknowledgement Alper Uysal acknowledges financial support from the Scientific and Technological Research Council of Turkey (TUBİTAK) BIDEB-2219 for their support of a Postdoctoral Research Program at the University of Kentucky for a year. Fig. 8. Serrated chip formation in (V = 80 m/min) (a) dry machining, (b) machining with MQL.
Fig. 9. Tool-chip frictional shear stresses in dry machining and machining with MQL (γ1 = 3°, r = 50 μm, t1 = 0.1 mm, w = 3 mm, PA/k = 0.9).
Fig. 10. Frictional shear stresses around the cutting tool edge and at the tool rake face [18].
4. Conclusion This study presents an experimental validation of the previously developed slip-line model. Orthogonal turning experiments were conducted on AISI 304 austenitic stainless steel under dry and MQL machining conditions to measure the cutting force components and maximum and minimum chip
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Procedia CIRP 00 (2019) 000–000
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Procedia CIRP 00 (2017) 000–000 Procedia CIRP 82 (2019) 124–129 www.elsevier.com/locate/procedia
17th CIRP Conference on Modelling of Machining Operations
17th CIRP Conference on Modelling of Machining Operations Validation of the slip-line model for serrated chip formation in orthogonal turning under dry MQL conditions Validation of the28th slip-line model forand serrated chip formation in orthogonal CIRP Design Conference, May 2018, Nantes, France turning under drya,b,and MQL conditions a Alper Uysal *, I.S. Jawahir A new methodology to analyze the functional and physical architecture of a University of Kentucky, Department of Mechanical Engineering and Institute for Sustainable Manufacturing (ISM), Lexington KY 40506, USA Alper Uysala,b, *, I.S. Jawahir existing products for an assembly oriented product family identification Yildiz Technical University, Department of Mechanical Engineering, Istanbul 34349, Turkey a
b
University of Kentucky, Department of Mechanical Engineering and Institute for Sustainable Manufacturing (ISM), Lexington KY 40506, USA * Corresponding author. Tel.: +90-212-383-2807 ; fax: +90-212-383-3024. E-mail address: [email protected] b Yildiz Technical University, Department of Mechanical Engineering, Istanbul 34349, Turkey a
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
* Corresponding Tel.:Supérieure +90-212-383-2807 fax: +90-212-383-3024. E-mail address: Écoleauthor. Nationale d’Arts et ;Métiers, Arts et Métiers ParisTech, [email protected] EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
Abstract
* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: [email protected]
In this study, the previously developed slip-line model for serrated chip formation was validated in orthogonal turning under dry and MQL Abstract (Minimum Quantity Lubrication) conditions. Face turning experiments were conducted on grooved AISI 304 austenitic stainless steel workpiece with tool inserts cutting edge radius of 50model μm. The andvalidated the maximum and minimum thicknesses were In this study, thehaving previously developed slip-line for cutting serratedforce chip components formation was in orthogonal turningchip under dry and MQL measured validate Lubrication) the model. Inconditions. dry cutting,Face the average prediction errors 9.44%, 4.78% and 7.69% for cutting, thrust, and resultant forces, Abstract (MinimumtoQuantity turning experiments wereare conducted on grooved AISI 304 austenitic stainless steel workpiece respectively. In machining with edge MQL,radius the average prediction errorsforce are 10.79%, 11.49% and maximum 2.46% forand cutting, thrust,chip andthicknesses resultant forces, with tool inserts having cutting of 50 μm. The cutting components and the minimum were respectively. In addition, the average prediction errors forproduct maximum and minimum chip4.78% thicknesses are determined 6.38% 9.12% in dry Inmeasured today’s business environment, towards more variety and isand unbroken. Due to thisas development, the need of to validate the model. Inthe drytrend cutting, the average prediction errors arecustomization 9.44%, 7.69% for cutting, thrust, andand resultant forces, cutting 7.79% and 4.35% in MQL, respectively. respectively. In machining with MQL, the average errors are 10.79%, and 2.46% for cutting, thrust, resultant forces, agile andand reconfigurable production systems emergedprediction to cope with various products11.49% and product families. To design and and optimize production respectively. In as addition, the average prediction for maximum and minimum chip are determined as 6.38% 9.12%aim in dry systems as well to choose the optimal producterrors matches, product analysis methods arethicknesses needed. Indeed, most of the knownand methods to © 2019aand The Authors. Published by Elsevier B.V. cutting 7.79% 4.35% in family MQL, respectively. analyze product orand one product on the physical level. Different product families, however, may differ largely in terms of the number and Peer-review under responsibility of Elsevier the scientific committee of The and 17thchoice CIRP Conference on Modelling of Machining Operations, nature ofThe components. This fact by impedes anB.V. efficient comparison of appropriate product family combinations for the production © 2019 Authors. Published in the person of the Conference Chair Dr Erdem Ozturk and Co-chairs Dr Tom Mcleay and Dr Rachid Msaoubi. © 2019 The Authors. Published by Elsevier B.V. system. A newunder methodology is proposed analyze existing products viewCIRP of their functionalonand physical architecture. aim is to cluster Peer-review responsibility of thetoscientific committee of Thein17th Conference Modelling of MachiningThe Operations Peer-review responsibility of the scientific committee of The 17th CIRPofConference on Modelling of the Machining these productsunder in new assembly oriented product families for the optimization existing assembly lines and creationOperations, of future reconfigurable Keywords: Modelling; turning; chip; lubrication in the person of theBased Conference Chair Dr Erdem and Co-chairs Tom Mcleayisand Dr Rachid Msaoubi. assembly systems. on Datum Flow Chain, Ozturk the physical structure Dr of the products analyzed. Functional subassemblies are identified, and a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the Keywords:between Modelling; turning;families chip; lubrication similarity product by providing design support to both, production system planners and product designers. An illustrative example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of 1. Introduction modelof to back-flow angle by utilizing the thyssenkrupp Presta France is then carried out to give a first industrial evaluation the predict proposed chip approach. previously developed universal slip-line model [5]. © 2017 The Authors. Published by Elsevier B.V. 1. Introduction model to predict chip back-flow angle by utilizing the In literature, there are several slip-line models to understand Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018. Nomenclature
previously developed universal slip-line model [5]. ap undeformed chip thickness Nomenclature and the mechanics metal operations. early BUE built-up edge line analyze models were developedofwith thiscutting assumption [1-9]. In Among undeformed chip thickness ak p studies,studies, the cutting tool[1] waspresented considereda asslip-line sharp, and the slipmaterial shear flow stress these Kudo model for built-uplength edge line models with were adeveloped assumption Among lBUE cutting machining built-up with edgethis (BUE). Maity [1-9]. and Das [2] 1.these Introduction and manufactured and/or k the product materialrange shear flowcharacteristics stress studies, Kudomodel [1] presented a slip-line modelstepfor of MQL minimum quantity lubrication developed a slip-line for machining with a parallel assembled in this system. In this context, the main challenge in lA cutting length machining with a built-up edge (BUE). and [3] Das and [2] P hydrostatic pressure at Point A type chip breaker, and investigated the Maity chip curl Due to the fast development in the domain of modelling and analysis is now not only to cope with single quantity developedCoulomb a slip-line modelatforthe machining a parallel steprMQL minimum cutting edge radius lubrication assumed friction chip-toolwith interface [4]. Fang communication and an ongoing trend of digitization and products, a limited product range or existing product families, hydrostatic pressure at Point A type chipintroduced breaker, aand investigated chip involving curl [3] chip and tP1A uncut chip thickness et al. [5] universal slip-linethemodel digitalization, manufacturing enterprises are facing important but also to be able to analyze and to compare products to define r assumed Coulomb friction at the chip-tool [4]. Fang V cutting edge speedradius curl and chip back-flow in machining with ainterface restricted contact challenges in today’s market environments: a continuing new product families. It can be observed that classical existing uncut chip t1 et al. and [5] introduced universal slip-line model involving w width of cutthickness tool, this modelawas validated by Fang and Jawahir chip [6]. tendency towards reduction of product development times and product families are regrouped in function of clients or features. cutting speed curl and back-flow in machining restricted contact γV1 rake angle Fang [7, chip 8] presented a slip-line modelwith for asharp cutting tools shortened lifecycles. In addition, thereand is and anJawahir increasing assembly orientedshear product families width of cut tool,predict and product this wasforces, validated Fang [6]. However, τw1 tool-chip frictional stress on theare toolhardly edge to SEfind. to themodel cutting chipbythickness tool-chip demand of customization, being at the same time in a global On the product family level, products differ mainly in two rake anglefrictional shear stress on the tool edge SB Fang [7,length. 8] presented a slip-line for sharp an cutting tools τγ21 tool-chip contact Fang and Jawahirmodel [9] proposed analytical competition with competitors all over the world. This trend, main characteristics: (i) the number of components and (ii) edge face SE the τ1rake tool-chip frictional shear stress on the tool rake to predict the cutting forces, chip thickness and tool-chip which is inducing the development from macro to micro type of components (e.g. mechanical, electrical, electronical). tool-chip frictional shear stress on the tool edge SB τ2 contact length. Fang and Jawahir [9] proposed an analytical markets, results in diminished lot sizes due to augmenting Classical methodologies considering mainly single tool-chip frictional shear stress on the tool rakeproducts face τrake product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the 2212-8271 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the scientific of The 17th CIRP on Modelling Machininglevel Operations, in the person of the To cope with this augmenting variety as committee well as to be able to Conference product structure on of a physical (components level) which Conference Erdem Ozturk and Co-chairs Dr B.V. Tom and Dr Rachid Msaoubi.difficulties regarding an efficient definition and 2212-8271 possible ©Chair 2019Dr The Authors. Published by Elsevier identify optimization potentials in Mcleay the existing causes Peer-review under responsibility of the scientific The 17th CIRP Conference on Modelling of Machining Operations, in theAddressing person of the this production system, it is important to havecommittee a preciseofknowledge comparison of different product families. and analyze the mechanics of metal cutting operations. In early
In literature, there aremethod; several slip-line understand Keywords: Assembly; Design Family identification studies, the cutting tool was considered asmodels sharp,toand the slip-
Conference Chair Dr Erdem Ozturk and Co-chairs Dr Tom Mcleay and Dr Rachid Msaoubi. 2212-8271 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the by scientific of The 17th CIRP Conference on Modelling of Machining Operations 2212-8271 © 2017 The Authors. Published Elseviercommittee B.V. 10.1016/j.procir.2019.04.006 Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
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Several slip-line models were presented subsequently for machining with rounded-edge cutting tools [10-16], and these models are more suitable for practice because of the inherent nature of the roundness of the cutting tools. Fang [10, 11] presented a slip-line model for rounded edge cutting tools and performed quantitative analyses to predict the cutting forces, chip thickness, tool-chip contact length and chip up-curl radius. Wang and Jawahir [12] developed a slip-line model for restricted contact grooved tools having a finite cutting edge radius to predict the cutting forces, chip thickness, chip up-curl radius, temperatures and flow stresses at the primary shear zone and at the tool-chip interface. Jin and Altintas [13] introduced and experimentally validated a slip-line model considering the stress variation in the material deformation region because of the cutting edge radius. Ozturk and Altan [14] proposed a slipline model for rounded edge tools and this model involved a dead metal zone on the rake face. Uysal and Altan [15,16] presented slip-line models for rounded edge [15] and worn rounded edge [16] cutting tools by assuming the existence of dead metal zone and experimentally validated these models. In these studies, the chip formation was considered as continuous. However, serrated chip formation occurs in machining of various materials such as stainless steels, titanium and nickelbased alloys, etc. These materials are generally considered as hard-to-machine materials. Early work by Manyindo and Oxley [17] presented a slip-line model for serrated chip formation in machining of stainless steel with a sharp cutting tool. More recently, Uysal and Jawahir [18] developed a slip-line model for serrated chip formation in machining with a rounded cutting edge. This slip-line model and its associated hodograph are given in Fig. 1. In machining of hard-to-machine materials, flood cooling by applying emulsion-based fluids is a common practice. But, these fluids consist of oils, water, and/or some additives. These chemicals adversely affect the environment and also employees [18, 19]. Therefore, environmental and societal concerns have required more sustainable machining operations. MQL (Minimum Quantity Lubrication) method has been developed as an alternative to flood cooling. In recent years, numerous studies on the usage of MQL in the machining of hard-tomachine materials have been performed [20-26]. Therefore, in this study, the slip-line model for serrated chip formation (Fig. 1), which was previously developed by the authors [18], was experimentally validated for machining under dry and MQL conditions for AISI 304 austenitic stainless steel.
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a Kennametal® Inc. CTCPN-544 tool holder with a rake angle of 3°. The cutting edge radius of the inserts was 50 μm. A new cutting edge was used for every cut to avoid the tool-wear effect.
Fig. 1. (a) Previously developed slip-line model for serrated chip formation, and (b) its hodograph [18].
2. Experimental studies To validate the developed slip-line model for machining under dry and MQL conditions, orthogonal turning experiments were conducted. The studied workpiece material was grooved AISI 304 austenitic stainless steel workpiece shown in Fig. 2. This workpiece material is very similar to AISI 321 workpiece material used in our previous work [18]. Face turning experiments were conducted on a HAAS TL-2 CNC lathe. The experimental set-up is shown in Fig. 3. All experiments were performed with Kennametal® Inc. TPGN220408 uncoated cemented carbide inserts mounted on
Fig. 2. Dimensions of AISI 304 austenitic stainless steel workpiece.
The cutting parameters were selected based on the manufacturer’s recommendations and the state-of-the-art review of literature for machining AISI 304 austenitic stainless steel, and these conditions are shown in Table 1. In MQL method, Coolube 2210EP metalworking lubricant was applied through a UNIST MQL system to the rake face at a 25 ml/h flow rate with 0.4 MPa of air pressure.
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3. Validation of the slip-line model with experimental results The previously developed slip-line model was validated using the conducted experimental results under dry and MQL conditions. Figs. 4-7 show the predicted and the average experimental cutting and thrust force components, resultant force, and maximum and minimum chip thickness values.
Fig. 3. Experimental set-up. Table 1. Cutting parameters used in machining of AISI 304 austenitic stainless steel. Cutting environment
Cutting speed, V (m/min)
Undeformed chip thickness, ap (mm)
Rake angle, γ1 (°)
Width of cut, w (mm)
Cutting length, l (mm)
Dry
60
0.1
3
3
10
Dry
80
0.1
3
3
10
Dry
100
0.1
3
3
10
60
0.1
3
3
10
80
0.1
3
3
10
100
0.1
3
3
10
MQL (rake face) MQL (rake face) MQL (rake face)
The cutting force components were measured by a Kistler 9121 3-component tool dynamometer during the experiments. After conducting the orthogonal machining tests, the maximum and minimum chip thicknesses were measured by Keyence VHX digital microscope having VH-Z250R real zoom lens. For this reason, the chip samples were mounted on epoxy, and metallurgically prepared by grinding and polishing processes using Buehler AutometTM 250 automatic grinder/polishing machine. In the metallurgical preparing process, the mounted samples were ground/polished by SiC sandpaper (#240) at 180 rpm with water and then by diamond paper (30 μm) at 180 rpm with water for 4 mins. For polishing, 9 μm diamond suspension was used at 180 rpm for 4 minutes, 6 μm diamond suspension was used at 180 rpm for 3 minutes, 3 μm diamond suspension was used at 180 rpm for 2 minutes and 1 μm and 0.05 μm Alumina suspensions were used at 150 rpm for 2 minutes, respectively. Average values of cutting force components and chip thickness were determined and recorded for all measured results from 3-4 measurements for each datapoint.
Fig. 4. Experimental and predicted cutting force components and the thrust force with varying cutting speed in dry cutting (γ 1= 3°, r = 50 μm, t 1= 0.1 mm, w = 3 mm, PA/k = 0.9, τ1/k = 0.7, τ2/k = 0.7, τrake/k = 0.9) (a) cutting force, (b) thrust force, (c) resultant force.
In dry cutting, the average prediction errors are 9.44%, 4.78% and 7.69% for cutting force, thrust force and resultant force, respectively (Fig. 4). For machining with MQL, the average prediction errors are 10.79%, 11.49% and 2.46% for cutting force, thrust force and resultant force, respectively (Fig. 5). The results show that the force predictions, using the proposed predictive model, are acceptable. Additionally, lower cutting forces are observed in MQL method than for dry cutting and the cutting forces decreased with increase in cutting speed as expected.
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Fig. 6. Experimental and predicted maximum and minimum chip thicknesses according to cutting speed in dry cutting (γ 1= 3°, r = 50 μm, t1 = 0.1 mm, w = 3 mm, PA/k = 0.9, τ1/k = 0.7, τ2/k = 0.7, τrake/k = 0.9) (a) maximum chip thickness, (b) minimum chip thickness.
Fig. 5. Experimental and predicted cutting force components and the thrust force with varying cutting speed in machining with MQL (γ1 = 3°, r = 50 μm, t1 = 0.1 mm, w = 3 mm, PA/k = 0.9, τ1/k = 0.6, τ2/k = 0.56, τrake/k = 0.72) (a) cutting force, (b) thrust force, (c) resultant force.
The average prediction errors for maximum and minimum chip thicknesses are determined as 6.38% and 9.12% in dry cutting (Fig. 6) and 7.79% and 4.35% in machining with MQL (Fig. 7), respectively. From these results, it can be said that the proposed slip-line model can make a good prediction of chip thickness in machining under dry and MQL conditions. Besides, the chip formation in dry cutting and MQL method can be seen in Fig. 8. The presence of tribo-layer in between chip-tool interface, ball bearing effect and mending effect might minimize the frictional force which reduces the chip thickening phenomenon under MQL application. Therefore, the saw-tooth formation can be seen clearly in MQL condition. In Fig. 9, it can be seen that the variation of tool-chip frictional shear stresses around the tool edge and at rake face (Fig. 10) with dry machining and machining with MQL. The results show that an effective lubrication caused a decrease in tool-chip frictional shear stresses, and this may be the reason for the reduction in cutting force values during machining with MQL.
Fig. 7. Experimental and predicted maximum and minimum chip thickness values for varying cutting speed in machining with MQL (γ 1= 3°, r = 50 μm, t1 = 0.1 mm, w = 3 mm, PA/k = 0.9, τ1/k = 0.6, τ2/k = 0.56, τrake/k = 0.72) (a) maximum chip thickness, (b) minimum chip thickness.
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thickness values. Based on the validation of the proposed slipline model, a good correlation was obtained between experimental and predicted results for machining under dry and MQL environments. In addition, it was observed from the solution of the model that an effective lubrication caused a decrease in tool-chip frictional shear stresses. In both conditions, the cutting force components decreased with increasing cutting speed and lower cutting force components were obtained under MQL condition. Besides, the saw-tooth chip formation was observed clearly in machining with MQL due to the presence of tribo-layer at the chip-tool interface. Acknowledgement Alper Uysal acknowledges financial support from the Scientific and Technological Research Council of Turkey (TUBİTAK) BIDEB-2219 for their support of a Postdoctoral Research Program at the University of Kentucky for a year. Fig. 8. Serrated chip formation in (V = 80 m/min) (a) dry machining, (b) machining with MQL.
Fig. 9. Tool-chip frictional shear stresses in dry machining and machining with MQL (γ1 = 3°, r = 50 μm, t1 = 0.1 mm, w = 3 mm, PA/k = 0.9).
Fig. 10. Frictional shear stresses around the cutting tool edge and at the tool rake face [18].
4. Conclusion This study presents an experimental validation of the previously developed slip-line model. Orthogonal turning experiments were conducted on AISI 304 austenitic stainless steel under dry and MQL machining conditions to measure the cutting force components and maximum and minimum chip
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