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Influence of tool flank wear considering tool edge radius on instantaneous uncut chip thickness and cutting force in micro-end milling

Abstract

Accurate theoretical analysis and modeling of instantaneous uncut chip thickness (IUCT) play a crucial role in the cutting force prediction of the micro-milling process. Tool wear and tool runout have a significant influence on the IUCT and become key factors to be considered. An IUCT model covering the influence of tool runout and tool flank wear considering tool edge radius is proposed. Based on this the prediction model of the cutting force is constructed in the micro-end milling process. Firstly, an actual tool radius model considering tool flank wear and tool edge radius is analyzed. The IUCT model is established by constructing the trochoidal trajectories of the current cutting edge and all cutting edges in the previous cycle considering tool flank wear and tool runout. Moreover, tool flank wear and tool runout are considered in the determination of cutter-workpiece engagement and the calibration of cutting force coefficients. Effectiveness of the established cutting force model is verified by micro milling experiments and statistical analysis. Results show that tool flank wear has a significant effect on the cutting forces of the three directions, and the influence of tool flank wear on the IUCT is small in a certain range. This work for predicting the IUCT and cutting force sheds new light on revealing various derived physical phenomena such as deformation, heat, and stress in the micro-cutting process. The instantaneous uncut chip thickness model covering the influence of tool runout and tool flank wear considering tool edge radius is proposed.The micro-milling cutting force based on instantaneous uncut chip thickness is predicted from the mechanism level.Effectiveness of the established cutting force model is verified by micro-milling experiments and statistic analysis.The influence of tool flank wear on the instantaneous uncut chip thickness and cutting force is analyzed.

article Article

date_range 2024

language English

link Link of the paper

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Gao Shuaishuai

Duan Xianyin

Zhu Kunpeng

Zhang Yu

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Featured Keywords

Micro-end milling

Cutting force

Instantaneous uncut chip thickness

Tool flank wear

Tool edge radius

Tool runout

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Effect of corrosion on flexural strength of reinforced concrete beams with polypropylene fibers

Abstract

An experimental study was performed to investigate the effects of polypropylene fibers on uncorroded and corroded reinforced concrete beams. Three different volume fractions of polypropylene fibers having 0, 0.5, and 1.5%, were tested at four corrosion levels of 0% and approximately 5, 7, and 9%. A full scale of an accelerated corrosion pool was used for the accelerated corrosion process. Reinforced concrete beams were used for an under monotonic bending test. The contribution of the actual corrosion levels of transverse and longitudinal reinforcement bars to the total corrosion levels were obtained from reinforcement bars fully extracted from concrete. Flexural strength, bond-slip, and moment-curvature relationships were examined for uncorroded and corroded reinforced concrete beams. A new model was developed to predict the flexural strength of corroded reinforced concrete beams. The proposed model for predicting the residual flexural strength of corroded beams was compared with test data published in previous studies. Furthermore, a novel model is presented for improved predictions between the actual and theoretically estimated corrosion mass losses, based on Faraday’s law, with the aid of fully extracted reinforcement bars. The model used to predict the flexural strength of corroded reinforced concrete beams with large sizes demonstrated good agreement with current and previously published literature data. In the case of corroded beams comprising differing amounts of polypropylene fibers, the performance of the corroded beams was limited by a fiber volume fraction of 1.5% at low corrosion levels.

article Article

date_range 2018

language English

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