Observations are made regarding the influence of cutting speed and friction on cutting force by way of finite element modeling. Simulations are validated by comparison of cutting forces and chip morphologies for the Al6061-T6. Analysis of cutting forces over a wide range of cutting conditions suggests an important role of the secondary shear zone in the decrease of cutting force as a function o...

The simulation of nanometric cutting of copper with diamond cutting tools, with the Molecular Dynamics method is considered. A 2D model of orthogonal nano-scale cutting is presented and the influence of the depth of cut and tool rake angle on chip morphology and cutting forces is investigated. For the analysis, three different depths of cut, namely 10Å, 15Å and 20 Å and four tool rake angles, n...

Determination of optimal conditions of machining parameters is important to reduce the production cost and achieve the desired surface quality. This paper investigates the influence of cutting parameters on surface roughness and natural frequency in turning of aluminum alloy AA2024. The experiments were performed at the lathe machine using two different cutting tools made of AISI 5140 and carbi...

The classical theorem of Hopf Bifurcation for the study of periodic solutions of ordinary differential equations (ODEs) at an equilibrium point has become the standard mathematical tool for reducing higher dimensional dynamical systems to lower dimensional systems, while at the same time preserving the emanating dynamics. The attraction for this tool is due to the fact that the classical Hopf t...

This study investigated the optimization of End milling of AISI 1018mild steel by various lubricants using the Grey relational analysis method. Quaker 7101, Blasocut strong 4000 and Velvex have been selected as lubricant. All the experiment are carried out at different cutting parameter (Number of Tool Flutes, Depth of cut, Spindle speed and Feed rate) in various lubricant assisted environment....

Over the past few decades, there has been a growing interest in modelling of machining processes. In this regard, smoothed particle hydrodynamics (SPH) is one of the latest methods used for that purpose. SPH is a powerful technique that can be used in handling problems of large deformation that are difficult to be tackled using traditional finite element methods. The current work aims to presen...

In Part II of this paper, a cutting force model for the micro-endmilling process is developed. This model incorporates the minimum chip thickness concept in order to predict the effects of the cutter edge radius on the cutting forces. A new chip thickness computation algorithm is developed to include the minimum chip thickness effect. A slip-line plasticity force model is used to predict the fo...

Finite Element Analysis (FEA) based techniques have become increasingly available to simulate metal cutting process and offer several advantages including prediction of tool forces, distribution of stresses and temperatures, estimation of tool wear, optimization of cutting conditions, tool edge geometry and coatings, and determination of residual stresses on machined surfaces. However, accuracy...

Surface roughness is used to determine and evaluate the quality of a final product in turned parts. In order to get better surface finish, the proper setting of cutting parameters is crucial before the process takes place. Titanium Grade 5 material is one whose surface hardness is high and it is used for making Aerospace engine components, titanium rod and ideal materials for medical implements...

This study investigates the effects of cutting parameters on surface roughness (Raμm ), cutting temperature (T0C) at the chip tool interface and the material removal rate (MRR mm3/min) during hard machining of AISI 1015 (43 HRC) steel using carbide insert under dry and spray impingement cooling environment. A combined technique using orthogonal array and analysis of variance (ANOVA) was employe...