Article
Engineering, Manufacturing
Binglin Li, Rui Zhang, Wen Qi, Benjie Li
Summary: The flow direction of a no-free chip is crucial for chip control and machining surface integrity. This study proposes a new analytical model for cylindrical turning that considers the influence of workpiece materials and tool nose radius on chip flow direction. The model divides the rounded edge into oblique cutting units and characterizes the thermomechanical process of chip formation using the unequal division shear zone method. The interaction forces of discrete chip units are calculated to determine the resultant chip flow direction, considering the interaction among constrained chip units as non-free chip flow. The study also analyzes the effects of material constitutive and cutting parameters on the flow direction of discrete chip and resultant chip using a thermomechanical coupling method. The predicted chip flow direction is validated with experimental values and Colewell's model, and finite element simulation is used for comparison, showing good agreement.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Polymer Science
Bin Yang, Hongjian Wang, Kunkun Fu, Chonglei Wang
Summary: In this study, an explicit finite element (FE) model was developed to predict cutting forces and chip morphologies of polymers. The model considered a dual fracture process, strain rate effect, and frictional behavior. Experimental results showed that the predicted fracture toughness, cutting forces, and chip morphologies were consistent with the experimental results. Parametrical analysis revealed that the friction coefficient had the greatest effect on cutting force.
Article
Automation & Control Systems
Haidong Yang, Yusong Wu, Junsheng Zhang, Huohong Tang, Weijie Chang, Juchen Zhang, Shunhua Chen
Summary: In this study, the cutting characteristics of Zr57Cu20Al10Ni8Ti5 (at.%) bulk metallic glass (Zr57 BMG) were compared with industrial pure zirconium (Zr702) during high-speed machining (100-350 m/min). It was found that despite the higher strength of Zr57 BMG, there was no significant difference in the main cutting forces between the two materials, which was attributed to the thermal softening of Zr57 BMG during machining. Furthermore, the surface characteristics and chip morphology changed as the cutting speed increased, with the worst surface quality obtained at a speed of 250 m/min.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
S. H. Chen, Q. Ge, J. S. Zhang, W. J. Chang, J. C. Zhang, H. H. Tang, H. D. Yang
Summary: Zr57 BMG showed excellent machinability at low-speed cutting with superior surface roughness and no crystallization. Scale-like patterns were observed on the machined surface due to plastic flow, which could be effectively suppressed by adjusting cutting parameters.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Engineering, Manufacturing
Janos Kundrak, Bernhard Karpuschewski, Zoltan Palmai, Csaba Felho, Tamas Makkai, Dmytro Borysenko
Summary: This article summarizes the results of a project to study the cutting force during milling, which includes analyzing the technology using FEM simulation and validating it through cutting force measurements. The calculations show the importance of the chip ratio in determining the specific features of the technology, and it is advisable to avoid a chip ratio of ap/fz = 1 from an energy perspective.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
S. S. Rajput, C. Upadhyay, S. Gangopadhyay, F. Fernandes
Summary: The present study aims to improve understanding of the machining performance of TiAlN coated tools in face milling of AISI 1045 medium carbon steel. Three different cutting conditions (roughing, finishing, and aggressive) were investigated and their effects on cutting forces, chip temperature, tool wear, surface roughness, and chip characteristics were analyzed. It was found that the highest cutting forces were observed in the roughing condition, while the aggressive mode of machining resulted in the highest chip temperature and wear. Various types of wear were observed, including material adhesion, coating delamination, diffusion wear, attrition wear, and abrasion wear. The results of cutting forces, chip temperature, surface roughness, and chip characteristics were correlated with tool wear, providing valuable information for selecting appropriate cutting conditions in face milling of AISI 1045 steel with TiAlN coated inserts.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2023)
Article
Automation & Control Systems
Zhiguo Dong, Yuchao Zhang, Hongbo Lei
Summary: This study used a two-phase flow of fluid abrasive to investigate the cutting force of abrasive flow machining (AFM). The slipping cutting factor and cutting factor were defined for AFM, and the theoretical equation for calculating these factors was given. Results showed that the finishing force of AFM is proportional to the pressure of the flow field on the workpiece surface, and the abrasive phase cutting factors are influenced by factors such as abrasive particle size and mass mixing ratio.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Arabinda Meher, Manas Mohan Mahapatra
Summary: Machinability analysis is essential for achieving better surface finish and minimum cutting force in the machining of materials used in automobile and aerospace industries. This study compared the machinability of RZ5 alloy and RZ5/8 wt.% TiB2 composite and analyzed the effects of cutting speed, feed rate, and depth of cut on cutting force, surface roughness, chip morphology, and tool wear. The results showed that machining RZ5 alloy required higher cutting force due to the formation of built-up edge, while abrasive tool wear was observed in the machining of RZ5/8 wt.% TiB2 composite. Additionally, the surface roughness increased with increasing feed rate and depth of cut for both materials.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2023)
Review
Engineering, Industrial
Alisson R. Machado, Leonardo R. R. da Silva, Felipe C. R. de Souza, Rahul Davis, Leandro C. Pereira, Wisley F. Sales, Wagner de Rossi, Emmanuel O. Ezugwu
Summary: This paper reviews recent research on the application of surface texturing in machining processes, highlighting the influencing parameters and common implementation methods to guide future related studies.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Automation & Control Systems
Delfim Joao, Otoniel Rangel, Nicolas Milliken, O. Remus Tutunea-Fatan, Evgueni Bordatchev
Summary: The development of micromachining technologies has been driven by the increase in convenience and value of products due to size and weight reduction. V-grooves have gained attention in micromachining due to their versatile use. This study introduces a new cutting strategy for V-grooves and compares its implementation with the commonly used strategy.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Chemistry, Physical
Pawel Zawadzki, Rafal Talar, Adam Patalas, Stanislaw Legutko
Summary: This study investigates the impact of cutting angle, cutting depth, and cutting direction on cortical bone machining, and confirms that even negative cutting angles can guarantee controlled cutting and have wider applications in surgical procedures.
Article
Automation & Control Systems
Chun Liu, Min Wan, Yun Yang
Summary: This study established a finite element method (FEM) model to characterize and classify chip morphologies of Inconel 718, revealing a transition of chip patterns from smooth to serrated with increasing cutting speed, as well as the disappearance of chip serration at higher speeds. The research provides insights into the metal cutting process of Inconel 718 and offers a theoretical framework for chip generation across a range of cutting speeds.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Automation & Control Systems
Solomon Ntshiniki Phokobye, Dawood Ahmed Desai, Isaac Tlhabadira, Rotimi Emmanuel Sadiku, Ilesmni Afolabi Daniyan
Summary: The purpose of this research is to compare the cutting performances of SiAlON, CBN and carbide cutting tools during a titanium machining process. A face milling operation was performed to determine the cutting forces, temperatures, vibrations, and surface roughness achieved during the machining of a titanium alloy. Response surface methodology was used to determine the experimental results for different cutting parameters.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Xianjun Kong, Guang Hu, Ning Hou, Na Liu, Minghai Wang
Summary: Laser-assisted cutting technology has gained attention in improving the machinability of difficult-to-machine materials in aviation. A 3D transient laser heating model was developed to predict the preheating temperature of the cutting layer. The study investigated the effect of cutting parameters on the magnitude, frequency, and amplitude of the cyclic cutting forces in both conventional machining and laser-assisted machining. It was found that laser assistance reduces material flow stress, cutting force magnitude, and amplitude, but increases the frequency of circulating cutting forces. Additionally, the effect of laser-assisted machining on reducing cutting force fluctuations and improving surface quality was explored.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Mechanics
F. Cepero-Mejias, V. A. Phadnis, K. Kerrigan, J. L. Curiel-Sosa
Summary: The study uses FE models to virtually assess a composite machining process, developing an original FE approach to emulate chip formation in machining of CFRP laminates. Composite damage initiation modes are evaluated via hybrid Puck-Hashin criteria, with mechanical properties of damaged elements degraded linearly. A novel strain-based element deletion criterion is applied to simulate chip release process reliably.
COMPOSITE STRUCTURES
(2021)
Article
Engineering, Mechanical
Filipe Figueiredo dos Santos, Sandro da Costa Silva, Alexandre Mendes Abrao, Berend Denkena, Bernd Breidenstein, Kolja Meyer
Summary: Surface integrity is crucial for the functional performance of mechanical components, and deep rolling is an important surface treatment method. The study found that deep rolling significantly improves surface finish, but excessive pressure and feed can increase roughness. Increasing the number of rolling passes, however, helps improve surface finish.
JOURNAL OF TRIBOLOGY-TRANSACTIONS OF THE ASME
(2021)
Article
Engineering, Manufacturing
Berend Denkena, Marc-Andre Dittrich, Siebo Stamm, Marcel Wichmann, Soren Wilmsmeier
Summary: This passage discusses the challenges faced by production systems, bio-inspired production systems, and the concepts of "Gentelligence" and "process-DNA," as well as their performance in different applications.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Berend Denkena, Alexander Kroedel, Sascha Beblein
Summary: The current state of the art shows that the friction behavior during machining is not yet fully understood, requiring further research. A novel method for analyzing friction mechanisms in machining was proposed in this study, revealing a significant influence of the sliding velocity of the chip on the coefficient of friction across a wide range of coating properties and cutting velocities.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
P. Kuhlemann, B. Denkena, T. Grove
Summary: Current research demonstrates that the mechanical surface-strengthening process of deeprolling is effective in improving the strength and life span of highly stressed components. Adjusting the process temperature during deep-rolling can further increase the mechanical life span, especially in soft machining operations where higher degrees of plastic deformation are induced in the subsurface.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2021)
Article
Engineering, Industrial
Berend Denkena, Alexander Kroedel, Arne Muecke, Lars Ellersiek
Summary: Surface quality is crucial in 5-axis ball end milling for determining component performance. This paper introduces a new method to predict surface defects, allowing for the selection of suitable process parameters without extensive experimental efforts.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Berend Denkena, Fritz Schinkel, Jonathan Pirnay, Soren Wilmsmeier
Summary: This paper introduces a new method for process-parallel Flexible Job Shop Scheduling based on quantum computing optimization, showcasing its good performance and practicality through a scientific benchmark and application to a real use-case. A managerial insight demonstrates how this approach can be integrated into existing production planning and control IT infrastructure.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2021)
Review
Engineering, Manufacturing
Berend Denkena, Benjamin Bergmann, Alexander Schmidt
Summary: This study investigates the capability of sensor fusion based on principal component analysis to monitor preload loss of single nut ball screws, by studying features of different preload levels of the ball screw through selecting different ball diameters. The results show that this method can reliably detect preload levels.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2021)
Article
Engineering, Industrial
Berend Denkena, Patrick Ahlborn
Summary: This paper presents a novel linear-rotary direct drive for machine tools, which combines linear and rotary movement in one drive to enhance the overall dynamics of the machine and reduce installation space.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Industrial
Carolin Kellenbrink, Nicolas Nuebel, Andre Schnabel, Philipp Gilge, Joerg R. Seume, Berend Denkena, Stefan Helber
Summary: This paper presents a cyber-physical system demonstrator for the maintenance, repair, and overhaul (MRO) of high-pressure turbine blades of aircraft engines. By using a virtual layer and a virtual twin, the system handles the variability in damage patterns and achieves individual, flexible, and economically optimized MRO actions. It showcases the combination and innovation of research results from multiple disciplines.
INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH
(2022)
Article
Engineering, Multidisciplinary
Lars Schoenemann, Oltmann Riemer, Bernhard Karpuschewski, Per Schreiber, Heinrich Klemme, Berend Denkena
Summary: The research has found that ultra-precision cutting based on digital surface twins can accurately predict surface features and characteristics, thus supporting the development of tool offset compensation methods and improving productivity.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2022)
Article
Engineering, Manufacturing
B. Denkena, A. Kroedel, M. Wilckens
Summary: The use of larger CBN grains in grinding can improve material removal rates for hardened steel components and achieve higher depths of cut. Grinding with coarse grains results in lower process forces, higher residual stress, and rougher surfaces, with minimal wear observed. In some cases, using larger grains can enhance tool performance and allow for higher feed rates.
PRODUCTION ENGINEERING-RESEARCH AND DEVELOPMENT
(2021)
Article
Engineering, Electrical & Electronic
Berend Denkena, Benjamin Bergmann, Matthias Witt
Summary: To achieve increased automation and flexibility in production, it is necessary to monitor component-specific characteristics and evaluate signals highly correlated with process quality. The use of material-specific cutting force improves the sensitivity of confidence limits to process errors, allowing the force-sensitive machine to substitute the dynamometer for process monitoring.
Article
Engineering, Manufacturing
Berend Denkena, Marc-Andre Dittrich, Hai Nam Nguyen, Konrad Bild
Summary: Self-optimizing process planning uses machine learning models to correlate process parameters with surface quality, automatically adjusting optimal parameters to achieve target roughness.
PRODUCTION ENGINEERING-RESEARCH AND DEVELOPMENT
(2021)
Article
Engineering, Manufacturing
Berend Denkena, Bernd-Arno Behrens, Benjamin Bergmann, Malte Stonis, Jens Kruse, Matthias Witt
Summary: This study predicts variations in dimension and cavities during cross-wedge rolling of shafts based on measured tool pressure. Multi-linear regression models are developed to determine the resulting diameters of the shaft shoulder, showing better prediction accuracy than models based on meta-data. The sensor concept for a new cross-wedge rolling machine and the approach for monitoring machining processes of workpieces with dimensional variations are presented for upcoming studies.
PRODUCTION ENGINEERING-RESEARCH AND DEVELOPMENT
(2021)
Article
Engineering, Manufacturing
Berend Denkena, Alexander Kroedel, Steffen Heikebruegge, Kolja Meyer, Philipp Pillkahn
Summary: This study investigates the impact of machining parameters on surface topography after deep rolling, and introduces a novel tool concept to explore the predictability of surface topography for milled specimens. By adjusting parameters gradually, the minimum pressure and lateral displacement conditions were identified to ensure accuracy in predicting surface topography.
PRODUCTION ENGINEERING-RESEARCH AND DEVELOPMENT
(2021)