Drilling of difficult-to-cut materials like titanium alloy is a complex machining operation. Due to the tool trajectory, the chip thickness changes along the cutting edges and during the tool movement. The aim of this study is to develop a drilling simulation model depending on the tool geometry and cutting data in order to control the final quality of the machined borehole through the size of burrs. First the geometry of the chip is modelled taking into account the parameters defining the tool trajectory and its geometry. An experimental study validates the modelling through vision camera observations. From this modelling it is possible to optimize the cutting data and cutting tool geometry in order to control the burrs size and thus the final quality of the borehole.
Article presents the results of turning process simulation research, carried out with a use of specialized software based on FEM method. On the basis of test results, temperature distribution on the rake face of the cutting tool was determined. C45 steel was adopted as the workpiece material, and the sintered carbide, without a protective coating – as the tool material. Material models of the C45 steel were built using the Johnson-Cook constitutive equation and material constants available in the literature. Research scope included the simulation of the orthogonal turning process, considering different levels of rake face wear.
The aim of the study is to analyze the friction coefficient in the machining zone during turning of a cylindrical workpiece of corrosion-resistant steel 17-4PH. The measurements were conducted during machining on the faces of a workpiece on a Masterturn 400 lathe with set machining parameters. A measurement stand enabling the recording of machining forces was proposed and installed. The theory of building computer simulation models and analysis of these models were also studied. The results of 2D computer simulations were used to analyse stress and friction coefficient in 10 points on the rake face of the tool.
The paper describes a measuring stand which allows recording physical phenomena during the turning. The stand allows
recording the temperature in the machining zone, cutting forces and fast-changing images. The temperature in the
machining zone was recorded using a FLIR SC 620 thermographic camera, and the obtained thermograms were analysed
using the ThermaCam Researcher application. A PHANTOM v 5.2 camera with a NIKKOR 200 mm prime lens and
CineViewer software was used to record and analyse the fast-changing images. The cutting forces were recorded in a
measuring path which comprised a KISTLER 9257B dynamometer, KISTLER 5070A charge amplifier, and DynoWare
software. The laboratory tests involved verification of the correct operation of this stand. The turning tests were
performed on an elongated workpiece made of hard-machinable steel. The analysis of results allows a verification of the
correct operation of the stand.