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Grzegorz M. Królczyk
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Lecture Notes in Mechanical Engineering
Grzegorz M. Królczyk
Piotr Niesłony
Jolanta Królczyk Editors
Industrial
Measurements
in Machining
Lecture Notes in Mechanical Engineering
Series Editors
Fakher Chaari, National School of Engineers, University of Sfax, Sfax, Tunisia
Mohamed Haddar, National School of Engineers of Sfax (ENIS), Sfax, Tunisia
Young W. Kwon, Department of Manufacturing Engineering and Aerospace
Engineering, Graduate School of Engineering and Applied Science,
Monterey, CA, USA
Francesco Gherardini, Dipartimento Di Ingegneria, Università Di
Modena E Reggio Emilia, Modena, Modena, Italy
Vitalii Ivanov, Department of Manufacturing Engineering Machine and Tools,
Sumy State University, Sumy, Ukraine
Francisco Cavas-Martínez, Departamento de Estructuras, Universidad Politécnica
de Cartagena, Cartagena, Murcia, Spain
Justyna Trojanowska, Poznan University of Technology, Poznan, Poland
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Editors
Industrial Measurements
in Machining
123
Editors
Grzegorz M. Królczyk Piotr Niesłony
Politechnika Opolska Politechnika Opolska
Opole, Poland Opole, Poland
Jolanta Królczyk
Politechnika Opolska
Opole, Poland
This Springer imprint is published by the registered company Springer Nature Switzerland AG
The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland
Preface
v
Contents
vii
viii Contents
Abstract. This paper presents the mathematical model for modelling and pre-
dicting the core roughness depth (Rk parameter) during hard turning with ceramic
inserts, using nonlinear function shape and a four-factorial plan experiments of the
first order. The independent mathematical modelling input parameters comprise
cutting speed (v), feed (f ), tool nose radius (r ε ) and depth of cut (ap ), with repeti-
tion in the middle point of the investigated hyperspace. The research was carried
out on working rings made of the steel C 55 (DIN), thermally enhanced on a 52
± 2 HRC, while the processing was done on the CNC lathe model OKUMA LB
15-II (C-1S). The measurement of working rings, obtaining the roughness profile
and calculation of the Rk parameters is done using the instrument Surtronic 3+
and the Talyprofile software. The results of the research are presented by nonlin-
ear mathematical models for the Rk parameter and coefficient K Rk obtained from
the ratio between Rk and the sum of Rpk, Rk and Rvk. According to the obtained
mathematical models, 3D graphs of the dependences between the Rk parameter,
coefficient K Rk and the input independent variables are also shown. The obtained
mathematical models are explained, and appropriate conclusions are given.
1 Introduction
It has been generally accepted that “hard turning” refers to turning of steels with hardness
greater than 45 HRC. Many researchers study the physical phenomena and the techno-
logical effects arising from hard turning. Out of all technological effects occurring on
the surface during hard turning, researchers pay mostly to the surface roughness and the
attempts to model and predict it. The driving force behind this refers to the notion of
replacing grinding with hard turning [1, 2].
Bartarya and Choudhury [1] investigate the cutting parameters effect on the cutting
force and the surface roughness during finishing hard turning AISI52100 grade steel and
develop the force and surface roughness regression models using full factorial design
of experiments. Mohruni et al. [2] propose empirical mathematical models for surface
roughness prediction depending on two hard turning input factors (cutting speed and feed
rate) on AISI D2 steel using Cubic boron nitride insert. They conclude that the cutting
speed and feed rate significantly affected the quality of machined surfaces. Furthermore,
the surface roughness value reduced (became smoother) by increasing the cutting speed.
On the other hand, as the feed rate increased, the surface roughness value increased
significantly. Mital and Mehta [3] have conducted an analysis of developed surface
prediction models and factors influencing the surface roughness. They developed the
surface finish models for aluminum alloy 390, ductile cast iron, medium carbon leaded
steel, medium carbon alloy steel 4130, and Inconel 718 for a wide range of machining
conditions defined by cutting speed, feed and tool nose radius. The experimental data
statistical analysis indicated that the type of the metal, speed and feed and tool nose
radius strongly influence the surface finish. Unlike the effect of the cutting speed, the
effects of feed and the tool nose radius on the surface finish were generally consistent
for all materials. Özel et al. [4] used a four-factor, two-level factorial design with 16
replications to determine the effects of the cutting tool edge geometry, the feed rate
workpiece hardness and the cutting speed on the resultant forces and surface roughness
in finishing hard turning of AISI H13 steel using CBN tools. They reported that the
cutting edge geometry had a significant effect on the surface roughness. Honed edge
geometry and lower workpiece surface hardness resulted in better surface roughness.
They also reported that the workpiece hardness, cutting edge geometry and cutting speed
significantly influenced the force component. Sundram and Lambert [5, 6] developed the
mathematical models for surface roughness prediction of AISI 4140 steel during the fine
turning operation using both TiC coated, and uncoated tungsten carbide throw away tools.
The parameters considered included speed, feed, cut depth, cut time, nose radius and
tool type. Agrawal et al. [7] predict surface roughness using three regression techniques
– multiple regression, random forest, and quantile regression. They concluded that the
random forest regression model represents a superior choice over multiple regression
models for predicting surface roughness during machining of AISI 4340 steel (69 HRC).
Generally, when the research talks about surface roughness prediction, it refers to
the arithmetical mean deviation Ra. Figure 1, shows two roughness profiles obtained
with cylindrical grinding and longitudinal turning with approximately equal values for
the arithmetical mean deviation Ra. The shapes of the surface roughness profiles clearly
show that these two profiles will behave differently during explanation even though they
had almost identical values of the Ra parameter.
On the other hand, Maurici et al. [8], using artificial neural networks, propose models
for parameters Rk, Rpk and Rvk for rough honing process. These parameters directly
correlate with the Abbott-Firestone (bearing area) curve and are also known as function
parameters. Grzesik [9] uses these parameters to examine the influence of tool wear on
surface roughness in hard turning using differently shaped ceramic tools. By changing
the shape of the bearing curves, he determines the impact of the wearing of the cutting
tool on the change of the shape of the surface roughness profile. Grzegorz et al. [10] use
the Rk, Rpk and Rvk parameters to compare the surface roughness of machined and of
fused deposition modelled parts.
Mathematical Modelling of Core Roughness 3
μm
0.5
а) -0.5
-1
-1.5
-2
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 mm
μm
1.5
1
0.5
b)
0
-0.5
-1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2 mm
Fig. 1. Surface roughness profiles obtained by cylindrical grinding (a) and longitudinal turning
(b), with approximately equal values for the arithmetical mean deviation Ra ≈ 0.2 μm
This means that the Rk, Rpk and Rvk parameters provide greater detail in describing
the surface roughness profile from a functional and explanation point of view. Hence,
the authors of this paper decided to develop a mathematical model for predicting the
core roughness depth, the Rk parameter, and a suitable correlation between Rk, Rpk and
Rvk expresses by the newly introduced coefficient K Rk during hard turning. Section 2
of this paper provides more details regarding the Rk parameter and the K Rk coefficient.
Rpk =
0.166μm Rpk =
0.36μm
Rk =
0.47μm
Rvk = Rk =
0.511μm 0.67μm
Rvk =
0.154μm
0 20 40 60 80 100 % 0 20 40 60 80 100 %
a) b)
Fig. 3. Material ratio curve and Rk, Rpk and Rvk parameters, for surface roughness profile from
Fig. 1, (a) cylindrical grinding and (b) longitudinal turning, obtained using the Talyprofile software.
Figure 3 clearly shows that the shape of the roughness profile material ratio curve of
the surface obtained during grinding drastically differs from the shape of the roughness
profile material ratio curve of the surface obtained during longitudinal turning. The values
of the Rk parameter also reflects this difference, i.e. Rk = 0.47 μm for the roughness
profile obtained from grinding, and for the roughness profile obtained from longitudinal
turning Rk = 0.67 μm.
We propose the introduction of a coefficient K Rk in order to obtain information about
the changes to the shape of the roughness profile obtained from longitudinal turning as
a function of the change of the cutting speed, feed, tool nose radius and depth of cut in
the investigated hyperspace. We know that we can divide the height of the roughness
profile into three parts. The core of the roughness profile, whose depth is defined by
the Rk parameter, the protruding peaks whose height is defined by the Rpk parameter
and protruding troughs whose depth is defined by the Rvk parameter. Any change of the
shape of the roughness profile changes the shape of the roughness profile material ratio
curve, thus directly impacting the values of the considered Rk, Rpk and Rvk parameters
and the K Rk coefficient.
We propose to determine the K Rk coefficient as follows:
Rk
KRk = (1)
Rpk + Rk + Rvk
If we calculate K Rk for the roughness profiles shown on Fig. 1, we will conclude that
K Rk = 0.41 for the roughness profile of the surface obtained with grinding, while for
the roughness profile of the surface obtained with longitudinal turning K Rk = 0.57. This
means that if we want to replace grinding with hard turning, we should make sure that
the depth of the roughness profile core expressed through Rk obtained from hard turning
approximately equals the depth Rk of the roughness profile obtaining from grinding.
In this regard, the introduction of the K Rk coefficient facilitates the comparison of
the roughness profiles using Rk in the total height (Rvk, Rk and Rpk), thus avoiding the
cases of equal Rk and different roughness profile shapes.
Mathematical Modelling of Core Roughness 5
3 Experimental Research
The research mathematically models the Rk parameters using the steel C 55 (DIN). The
material was prepared in the form of working rings, thermally enhanced on a 52 ± 2
HRC. The processing was done using a CNC lathe model OKUMA LB 15-II (C-1S)
with a variable spindle speed 38–3800 rpm, feed rate 0.001–1000 mm/rev and 15 kW
spindle drive motor. For the processing we used a cutting tool holder CSRNR 25 × 25
M12H3 (HERTEL) with κ = 75°; κ 1 = 15°; γ = −6°; λ = −6°; and ceramic cutting
inserts HC2 from the producer NTK-Cutting tools. In order to avoid the cutting tool
wearing effect, during processing we always used a new cutting edge.
We measured the working rings, obtained the roughness profile and calculated the
Rk parameters using the instrument Surtronic 3+ and the Talyprofile software. As a λc
profile filter we used a Gaussian filter with an appropriate sampling length. We used two
sampling lengths of 0.25 mm and 0.8 mm depending on the value of RS m .
The mathematical modeling of the Rk parameter and the K Rk coefficient will make
use of the nonlinear function shape and a four-factorial plan experiments from the first
order. The independent mathematical modeling input parameters comprise cutting speed
(v), feed (f), tool nose radius (r ε ) and depth of cut (ap ), with repetition in the middle
point of the investigated hyperspace. Table 1 shows the values of the independent input
parameters.
Sr. no. Parameters Level 1 (low) Level 2 (central point) Level 3 (high)
1 Cutting speed (v), m/min 67 94 133
2 Feed (f ), mm/rev 0.1 0.17 0.3
3 Depth of cut (ap ), mm 0.4 0.56 0.8
4 Tool nose radius (rε ), mm 0.8 1.2 1.6
After the mathematical processing of data for the Rk and K Rk values we obtained the
following mathematical models:
In the mathematical model for the Rk parameter, Eq. 2, the significant independent
variables include the feed (f ) and the tool nose radius (r ε ), while the insignificant ones
include cutting speed (v) and depth of cut (a). This means that an increase in the feed
(f ) leads to an increase of the value of the Rk parameter and an increase of the radius
(r ε ) reduces the value of the Rk parameter. The feed (f ) has a much greater effect than
the radius (r ε ).
In the mathematical model for the K Rk coefficient, Eq. 3, the significant independent
variables include only the tool nose radius (r ε ). Although the value of the exponent for
the cutting speed (v) comes close to the value of the exponent for the tool nose radius
Mathematical Modelling of Core Roughness 7
(r ε ), still mathematically the cutting speed (v) is not a significant input variable in this
mathematical model. Although the significant input variable here is the tool nose radius,
still the value of the exponent is small. The small value of the exponent for the tool nose
radius (r ε ) approximately equal to the value of the exponent for the cutting speed (v),
suggests that, generally, the shape of the roughness profile obtained from hard turning
does not significantly change in the investigated hyperspace. Interestingly, the exponent
of the tool nose radius (r ε ) has a positive sign, as opposed to the negative sign in Eq. (2).
This suggests that an increase in the tool nose radius (r ε ) leads to an increase in the
K Rk coefficient, i.e. the share of the Rk parameter. This means that an increase in the
tool nose radius, relative to a several times smaller feed, leads to a loss of the strictly
deterministic character of the roughness profile. This also applies to the influence of the
cutting speed, whose increase (of the cutting speed) can lead to vibrations during the
cutting process and a disruption of the strictly deterministic character of the roughness
profile.
Figures 4 and 5 also show 3D graphs of the dependences between the Rk parameter
and K Rk and the independent input variables.
Fig. 4. 3D graphs of the dependences between the Rk parameter and the independent input
variables (the feed (f ) and tool nose radius (r ε )).
Fig. 5. 3D graphs of the dependences between the K Rk parameter and the independent input
variables (the cutting speed (v) and tool nose radius (r ε )).
8 M. Tomov et al.
5 Conclusion
This research and the mathematical models for the Rk parameter and the K Rk showed
that:
– The significant input variables for the modelling of the Rk parameter include the feed
(f ) and the tool nose radius (r ε ), while cutting speed (v) and depth of cut (a) constitute
the insignificant variables. The Rk parameter directly correlates with the feed, i.e. an
increase in the feed will produce an increase of the Rk parameter On the other hand,
an increase in the tool nose radius (r ε ) produces a reduction in the Rk parameter, i.e.
the former inversely correlates to the latter. The feed has a greater impact than the
tool nose radius, reflected in the values of the respective exponents. If we analyze
the well-known theoretical equation for the maximum height of the roughness profile
Rt = f 2 /8r ε we will conclude that the above, regarding Rk applies here too. This
means that by nature, Rk behaves identically as the surface roughness profile height
parameters.
– The K Rk coefficient model, the Eq. 3, and the exponents of the input variables suggest
that there does not exist a dominant input parameter (cutting parameter) impacting the
value of the K Rk coefficient. Physically, this means that the roughness provide does not
change its shape significantly as a result of changes to the input parameters. The share
of Rk in the overall height of the roughness profile does not change drastically. The
same applies to Rpk and Rvk as well. This conclusion shows that, when attempting
to replace grinding with hard turning, one must consider the shape of the surface
roughness profile. Hard turning generates a deterministic (periodic) roughness profile
shape while grinding generates a stochastic (non-periodic) roughness profile shape,
i.e. roughness profiles with different exploitation characteristics.
In the future, the authors of this research propose to extend this research to other
hard materials, using various cutting inserts for processing hard materials, in order to
confirm and improve the results obtained from this research and make them more precise.
In addition, we need to think how to reduce the value of the Rk parameter, for an
unchanged height of the roughness profile obtained from longitudinal hard turning, in
order to converge even more to the roughness profile obtained from grinding.
References
1. Bartaryaa, G., Choudhuryb, S.K.: Effect of cutting parameters on cutting force and surface
roughness during finish hard turning AISI52100 grade steel. Procedia CIRP 1, 651–656 (2012)
2. Mohruni, A.S., Yanis, M., Edwin, K.: Development of surface roughness prediction model
for hard turning on AISI D2 steel using Cubic Boron Nitride insert. Jurnal Teknologi (Sci.
Eng.) 80(1), 173–178 (2018)
3. Mittal, A., Mehta, M.: Surface finish prediction models for fine turning. Int. J. Prod. Res.
26(12), 1861–1876 (1988)
4. Özel, T., Hsu, T.K., Zeren, E.: Effects of cutting edge geometry, workpiece hardness, feed
rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13
steel. Int. J. Adv. Manuf. Technol. 25(3–4), 262–269 (2005). https://doi.org/10.1007/s00170-
003-1878-5
Mathematical Modelling of Core Roughness 9
5. Sundaram, R.M., Lambert, B.K.: Mathematical models to predict surface finish in fine turning
of steel, Part 1. Int. J. Prod. Res. 19(5), 547–556 (1981)
6. Sundaram, R.M., Lambert, B.K.: Mathematical models to predict surface finish in fine turning
of steel, Part 2. Int. J. Prod. Res. 19(5), 557–564 (1981)
7. Agrawal, A., Goel, S., Rashid, W.B., Price, M.: Prediction of surface roughness during hard
turning of AISI 4340 steel (69 HRC). Appl. Soft Comput. 30, 279–286 (2015)
8. Maurici, S.A., Irene, B.C., Xavier, L.P.: Neural network modelling of Abbott-Firestone
roughness parameters in honing processes. Int. J. Surf. Sci. Eng. 11(6), 512–530 (2017)
9. Grzesik, W.: Influence of tool wear on surface roughness in hard turning using differently
shaped ceramic tools. Wear 265(3–4), 327–335 (2008)
10. Grzegorz, K., Pero, R., Stanislaw, L.: Experimental analysis of surface roughness and surface
texture of machined and fused deposition modelled parts. Tehnički vjesnik 21(1), 217–221
(2014)
11. ISO 13565-2:1996, Geometrical Product Specifications (GPS) - Surface texture: Profile
method; Surfaces having stratified functional properties - Part 2: Height characterization
using the linear material ratio curve
12. Surface Texture, Contour Measuring Instruments. Explanation of Surface Characteristic
Standards. https://inspectionengineering.com/uploads/2018/03/SurfaceFinishExplain
Unified Mathematic and Geometric Model
of Cutting Edge Separation with Corner Radius
in Turning
Abstract. In modern multiuse cutting tools with insert (e.g. with superfinishing
edge or Wiper), such a cutting edge is made without documenting the basics for
optimizing its dimensions. The article presents a generalized edge wear model in
the surroundings of a rounded tip. In this sense the suggested solution is a novelty
as it makes possible to specify the edge working conditions by modifying the
edge corner and to adapt different tools for various cutting parameters established
for creating a machined surface. The matter described in the article elaborates on
patent number PL 173536 B1 where the usefulness of the solution for other tools
(cutters, reamers, drills) was described. After the suggested works on the edge
tip, due to the load along the cutting edge with the edge corner radius and along
the cutting edge surface, always greater than zero and determining in both cases
unit forces, it was possible to solve the mechanics of wear in the surroundings of
the edge corner tip. The obtained model allows defining problems connected with
the created unevenness on the machined surface. If plasticity phenomena in the
cutting zone are taken into consideration, it can be proved that there is a group of
wear marks after multiple passes of the edge tip in a disorganized random manner.
1 Introduction
The main objective of the article was to develop a new model of the course of wear of the
clearance part located on corner top, which through its direct contact with the machined
surface, exerts impact on creation of its surface.
As the cutting process progresses, marks of wear can be noticed on the tool’s active
surface [1, 2]. The marks image depends on how the tool angle is shaped geometrically.
With a view on this, the most generic case of a tool with a circle-sector shaped edge
was examined. The observed marks on a turning tool edge were depicted in Fig. 1.
Three areas were marked on it, characterized by different mechanics and image of the
marks. Differences between those images are seen between the areas I, II, III (Fig. 1).
This depends on: cutting conditions, workpiece material of type, and strength of tool
material. What needs to be mentioned here are the wear marks on the flank face or lack
of a grooved mark on the tool face. In the cut layer, under the curvature of the cutting
edge, there is a layer of plastic deformed material and it is up to approximately 0,2 mm
depth. The thickness of the layer is marked in Fig. 1 with a dotted line, while the area is
spotted.
As the wear increases, a characteristic point where the cutting edge cuts the wrought
layer appears in area I. The location of this point determines the cutting depth and a
concentrated wear mark whose width is connected with the depth of the wrought layer
appears around that point. The increased temperature in this area and the access of air
from the edge open side intensify the wear growth, which manifests itself with a long
local abrasion mark. In area II the abrasion adopts the shape of a rectangular strip that
increases in width as the machining progresses. In area III the wear image is the result
of highly complex mechanisms. In accordance with the previously discussed model,
what is undergoing changes in the cutting zone is the layer thickness so that h < hmin .
This happens in particular when the feed (f) is less than 0,2 mm per revolution, i.e.
f < 0,2 mm/rev). [5, 6]. The mechanics of changes in tool edge apex geometry were
examined for such geometric conditions.
A few articles have attempted to explain the cutting edge operation. The findings
in [3] regarding the solution of turning tool wear are limited to value VB. This review
covers cutting operation on its main cutting surface and reports on VBA, B, C, and N.
Whereas, the auxiliary cutting surface describes VBr.
Value of VB wear does not influence the surface roughness parameters, while VBr
directly modifies the unevenness set. The h adopted by the Author [4] does not take into
consideration cutting force components, yet it considers only the geometric modeling.
It specifically refers to cylindrical face milling, and not to turning [4].
The articles [7–9, 13–16] on cutting edge work and mathematical modeling of cutting
forces describes the conditions during process milling. In the case of turning, the cutting
12 S. Borys and Ż. Łukasz
edge has been described but without the wear tool being consumed and without affecting
the rounding radius of the cutting edge rn [10–12]. In the other publications [17–21] the
values of tool wear are presented but without describing their actual impact on the
mechanism of separation with the wear tool. The papers [22–26] presents the corners
radius of the tool rn , but without referring to the limited possibility of chip formation due
to the minimum thickness of the cutting layer, as shown in the previously publications
[5, 6] especially in the vicinity of the corner tip of the tool and its image.
Apart from the geometric conditions it was assumed that, as a result of the wear, the tool
is shortened by value KE. Angle λs would not contribute in any significant way to the
discussion, but a correction including dislocation of the point on the tool edge apex has
been included.
Fig. 2. a) simplified geometric model of cylinders intersecting, where one has radius R, b) location
of the characteristic points on the tool edge in relation to the workpiece axis.
Unified Mathematic and Geometric Model of Cutting Edge Separation 13
A circle, whose center lies in the place marked with S(Sx, Sy, Sz) point, was inscribed
on the flank surface for γf > 0 (Fig. 2b). Axis of the cylinder circumscribed on the tool
apex also passes through this point. The distance between the cylinders’ axes, considering
the wear values and impact of the rake angle, will be:
Sy = R + rε − (1)
In this Eq. (1), apart from the sum of cylinders’ radiuses, there is a value marked with
that is the sum of radial traverse, forced by the wear and Ys adjustment caused by
the rake angle γf (Fig. 2b). This results from the fact that when the rake angle is γf =
0, point Pmax , furthest on the edge tool apex, intersects with point Pteor , corresponding
to the turning diameter. When rake angle γf = 0 and tilt angle of the main cutting edge
λs = 0, relevant tool traverse, which decreases the distance between cylinders’ axes by
value Ys, needs to be taken into consideration. In the rear plane, in a section crossing
through the apex point Pmax , when the value of abrasion VBr on flank surface is known,
radial tool wear KE can be calculated on basis of the following relation (2):
VB r tg αp
KE = (2)
1 − tg γp tg αp
We looked for point Y = Ys (Fig. 2), by which an analytical axis distance must be
shortened. During wear tool VBr (Fig. 1) on the corner radius rε , which is expected value
Ys, then shortened by on value KE (2).
Then we get the final Eq. (4) is therefore the sum of Eqs. (2) and (3).
From Eq. (4) Ys allows to explain the distance between the axis of the rotation and
the substitute plane PY II PXOZ.
Whereas Y = R, when R is half workpiece diameter D (Fig. 2).
Ys = R − R2 − rε2 tg2 γf (4)
Equation of the circle in a plane parallel to the basic plane Pr with center coordinates Sx
= 0, Sy = R + rε − , Sz = 0 in accordance with the system in Fig. 2a, can be written
down as follows:
Fig. 3. Auxiliary diagrams for determining equations of the cylinder’s generating lines: a) after
rotating the line by angle αf , b) after rotating by angle αp .
On plane XOZ the cylinder is rotated by angle αf , therefore the generating line of the
cylinder should cross axis Z at this angle, as demonstrated in Fig. 3a. Similarly, in plane
YOZ, the cylinder’s generating line is rotated by angle αp . Equation of the line passing
through two points m and m , which is also the equation of the cylinder generating line,
can be drawn from the following relation (6) and (7):
X0 − X
= tg αf (6)
0−Z
Where after conversion, expression for Z is determined
X − X0
Z= (7)
tg αf
Relevant dependences, but in YOZ plane, give (8)
Y0 − Y
= tg αp (8)
0−Z
The final equation of line, crossing through points m and m and rotated by angle αf and
αp can be written down as (9):
X − X0 Y0 − Y
Z= = (9)
tg αf tg αp
After determining from the system of equations
X = X0 + Z tg α f
(10)
Y = Y0 + Z tg α p
And after replacing in the circle Eq. (3) the following is obtained Eq. (11)
2 2
X0 + Z tg αf + Y0 + Z tg αp − R − rε + KE + Ys = rε2 (11)
When each point on the generating line also lies on the cylinder’s surface in the adopted
tool - workpiece system (Fig. 2a), and the equation of the cylinder circumscribing the
workpiece machined surface has the following form:
Z 2 + Y 2 = R2
2 (12)
X + Z · tgαf + Y + Z · tgαp − R − rε + KE + Ys = rε2
Unified Mathematic and Geometric Model of Cutting Edge Separation 15
Then the solution is a closed space curve which is the edge of intersection of
intersecting cylinders. The equations obtained as a result of equation conversion (2)
expression
Y = R2 − Z 2 (13)
replaced in Eq. (12) cannot be ousted and for this reason the system of Eqs. (12) is
difficult to solve. The solution can be facilitated by adopting known values of variable Z
from the range of –R < Z < +R Z values, for which discrimination of quadratic equation
is greater than zero, in the field of X, Y, Z data for the cylinders intersecting curve.
After multiplying the components and comparing the general equation of a 2nd order
curve
AX 2 + BXZ + CZ 2 + DX + EZ + F = 0 (16)
A = 1 (17)
B = 2 tg αf (18)
D = 0 (20)
E = tg αp (KE + Ys − rε ) (21)
16 S. Borys and Ż. Łukasz
AW < 0 (25)
Fig. 4. Auxiliary diagram for calculating coordinates of the ellipse’s characteristic points.
As a result, the obtained curve is the equation of the actual ellipse. After calculating
the necessary auxiliary data and inserting them into the ellipse Eq. (15) characteristic
points P1 , P2 , P3 and P4 can be established that describe the ellipse section, limited with
rake surface, as illustrated in Fig. 4.
When the rake angle γf is greater than zero, equation of line which will be the edge
of intersection of PY place with the plane crossing through the rake surface needs to be
inserted into (26), i.e.
Z = −(X + rε ) tg γf (26)
B = −2rε 1 − tg αf tg γf tg αf tg γf + 2 tg αp tg γf −rε tg αf tg γf − rε + KE + Ys
(29)
2
C = rε2 tg2 αf tg2 γf + −rε tg αf tg γf − rε + KE + Ys − rε2 (30)
A X2 + BX + C = 0 (31)
For point P3 , corresponding to intersection of the ellipse with its longer axis, after
substituting equation of the line in Eq. (15)
Z = −X ctg αf (34)
Roots of Eqs. (33) and (35) are the sought coordinates of points P3 and P4 of the ellipse
fragment (Fig. 4). When angle αf is low, then the difference between the coordinates of
points P3 and P4 is negligible in the calculations.
Fig. 5. Auxiliary diagram for calculating width of the abrasion mark on the transitory flank
surface.
18 S. Borys and Ż. Łukasz
The auxiliary cutting edge is rectilinear and transforms into a curved edge in point
B, as demonstrated in Fig. 5. When the axial tool wear KE obtains value higher than YB ,
it means that when
KE ≥ YB dla YB = rε 1 − cos κr (36)
In this expression VBr is the height of abrasion on the auxiliary flank surface. The
obtained wear mark width X1 + X2 (Fig. 4) will then be greater than results from
solution (32), which is due to the fact that as the wear progresses, the point located on
the circle moves onto the auxiliary edge.
In this work, the experimentally recorded curves of the abrasion ellipses correspond-
ing to subsequent wear stages are plotted on the projection.
In Fig. 7 the corner wear image and machined surface fragment were put together.
This figure shows the resemblance of the observed images that were collected while
illuminating them with two light beams – blue and red.
Unified Mathematic and Geometric Model of Cutting Edge Separation 19
Fig. 7. Composition of two images: image of wear traces on the tip of cutting part and
corresponding image of traces on the machined surface
It should be noted that many more details are made visible with the optic method, in
contrast to 2D or 3D records on profilometers. The wear marks measured by increasing
cutting time present a growth in the abrasion dimensions, which was presented in Fig. 8
as an example.
Fig. 8. Summary of wear marks, along the rounding of the corner radius for different cutting
times
6 Conclusions
The vast amount of literature data concerning VBr changes that are dependent on time
has encouraged the Authors to write down the following conclusions, focusing especially
on some new aspects:
1. Solutions of the equations allow us to generalize the model of contact of two warped
rollers and changes in the location of their axes towards one another due to the
progressing tool wear.
20 S. Borys and Ż. Łukasz
2. The distance between the axes remains unchanged and wear of one of them changes
the contact area.
3. As seen on the model, unevennesses in the diffusion area that make up the surface
roughness have been modified.
4. This results from multiple passes of the machined surface across the abrasion width
at the edge of top (Fig. 7 and 8).
References
1. Brammertz, P.H.: Die Enstehung der Oberflächenerauheit beim Feindrehen, Industrie
Anzeiger, 2 (1961)
2. Gieszen, C.A.: Bas seitliche Verguetschen des Werkstoffes auf den Oberfläehen feingedrehter
Werkstücke, Fertigung, 5 (1971)
3. Mikołajczyk, T., Nowicki, K., Kłodowski, A., Pimenov, D.Y.: Neural network approach for
automatic image analysis of cutting edge wear. Mech. Syst. Signal Process. 88, 100–110
(2017)
4. Pimenov, D.Y.: Geometric model of height of microroughness on machined surface taking
into account wear of face mill teeth. J. Frict. Wear 34(4), 290–293 (2013)
5. Storch, B., Zawada-Tomkiewicz, A.: Distribution of unit forces on the tool edge rounding in
the case of finishing turning. Int. J. Adv. Manuf. Technol. 60(5–8), 453–461 (2012)
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the case of constrained turning. Int. J. Mach. Tools Manuf. 57, 1–9 (2012)
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Another random document with
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questionable as it was in every respect, was sure to meet with general
approbation.
Before Captain Green and the others had been many days in
custody, strange hints were heard amongst them of a piratical attack
they had committed in the preceding year upon a vessel off the coast
of Malabar. The African Company had three years ago sent out a
vessel, called the Speedy Return, to India, with one Drummond as its
master, and it had never since been heard of. It was concluded that
the people of the Worcester had captured the Speedy Return, and
murdered its crew, and that Providence had arranged for their
punishment, by sending them for shelter from a storm to the
neighbourhood of Edinburgh. Vainly might it have been pointed out
that there was no right evidence for even the fact of the piracy, still
less for the Speedy Return being the subject of the offence. Truth and
justice were wholly lost sight of in the universal thirst for vengeance
against England and its selfish mercantile companies.
Green, the captain of the Worcester, Mather, the chief-mate,
Reynolds, the second-mate, and fifteen others, were tried at this date
before the Court of Admiralty, for the alleged crime of attacking a
ship, having English or Scotch aboard, off 1705.
the coast of Malabar, and subsequently
murdering the crew—no specific vessel or person being mentioned as
the subjects of the crime, and no nearer date being cited than the
months of February, March, April, or May 1703. The jury had no
difficulty in bringing them in guilty, and they were all condemned to
be hanged on the sands of Leith, the usual place for the execution of
pirates.
The English government was thrown into great anxiety by this
violent proceeding, but they could make no effectual resistance to the
current of public feeling in Scotland. There the general belief in the
guilt of Green and his associates was corroborated after the trial by
three several confessions, admitting the piratical seizing of
Drummond’s vessel, and the subsequent murder of himself and his
crew—confessions which can now only be accounted for, like those of
witches, on the theory of a desire to conciliate favour, and perhaps
win pardon, by conceding so far to the popular prejudices. The queen
sent down affidavits shewing that Drummond’s ship had in reality
been taken by pirates at Madagascar, while himself was on shore—a
view of the fact which there is now ample reason to believe to have
been true. She also sent to the Privy Council the expression of her
desire that the men should be respited for a time. But, beyond
postponement for a week, all was in vain. The royal will was treated
respectfully, but set aside on some technical irregularity. When the
day approached for the execution of the first batch of the
condemned, it became evident that there was no power in Scotland
which could have saved these innocent men. The Council, we may
well believe, would have gladly conceded to the royal will, but, placed
as it was amidst an infuriated people, it had no freedom to act. On
the fatal morning (11th April), its movements were jealously watched
by a vast multitude, composed of something more than the ordinary
citizens of Edinburgh, for on the previous day all the more ardent
and determined persons living within many miles round had poured
into the city to see that justice was done. No doubt can now be
entertained that, if the authorities had attempted to save the
condemned from punishment, the mob would have torn them from
the Tolbooth, and hung every one of them up in the street. What
actually took place is described in a letter from Mr Alexander
Wodrow to his father, the minister of Eastwood: ‘I wrote last night,’
he says, ‘of the uncertainty anent the condemned persons, and this
morning things were yet at a greater uncertainty, for the current
report was that ane express was come for a reprieve. How this was, I
have not yet learned; but the councillors 1705.
went down to the Abbey [Palace of
Holyrood] about eight, and came up to the Council-house about
nine, against which time there was a strange gathering in the streets.
The town continued in great confusion for two hours, while the
Council was sitting, and a great rabble at the Netherbow port. All the
guards in the Canongate were in readiness if any mob had arisen.
About eleven, word came out of the Council [sitting in the Parliament
Square] that three were to be hanged—namely, Captain Green,
Mather, and Simson. This appeased the mob, and made many post
away to Leith, where many thousands had been [assembled], and
were on the point of coming up in a great rage. When the chancellor
came out, he got many huzzas at first; but at the Tron Kirk, some
surmised to the mob that all this was but a sham; upon which they
assaulted his coach, and broke the glasses, and forced him to come
out and go into Mylne’s Square, and stay for a considerable time.
‘The three prisoners were brought with the Town-guards,
accompanied with a vast mob. They went through all the Canongate,
and out at the Water-port to Leith. There was a battalion of foot-
guards, and also some of the horse-guards, drawn up at some
distance from the place of execution. There was the greatest
confluence of people there that ever I saw in my life, for they cared
not how far they were off, so be it they saw. Green was first execute,
then Simson, and last of all Mather. They every one of them, when
the rope was about their necks, denied they were guilty of that for
which they were to die. This indeed put all people to a strange
demur. There’s only this to alleviate it, that they confessed no other
particular sins more than that, even though they were posed anent
their swearing and drunkenness, which was weel known.’[375]
Total, £411,117 : 10 : 00
‘This sum, no doubt, made up by far the greatest part of the silver
coined money current in Scotland at that time; but it was not to be
expected that the whole money of that kind could be brought into the
bank; for the folly of a few misers, or the fear that people might have
of losing their money, or various other dangers and accidents,
prevented very many of the old Scots coins from being brought in. A
great part of these the goldsmiths, in aftertimes, consumed by
melting them down; some of them have been exported to foreign
countries; a few are yet [1738] in private hands.’[390]
Ruddiman, finding that, during the time 1707.
between December 1602 and April 1613,
there was rather more estimated value of gold than of silver coined in
the Scottish mint, arrived at the conclusion (though not without
great hesitation), that there was more value of gold coin in Scotland
in 1707 than of silver, and that the sum-total of gold and silver
money together, at the time of the Union, was consequently ‘not less
than nine hundred thousand pounds sterling.’ We are told, however,
in the History of the Bank of Scotland, under 1699, that ‘nothing
answers among the common people but silver-money, even gold
being little known amongst them;’ and Defoe more explicitly says,
‘there was at this time no Scots gold coin current, or to be seen,
except a few preserved for antiquity.’[391] It therefore seems quite
inadmissible that the Scottish gold coin in 1707 amounted to nearly
so much as Ruddiman conjectures. More probably, it was not
£30,000.
It would appear that the Scottish copper-money was not called in
at the Union, and Ruddiman speaks of it in 1738 as nearly worn out
of existence, ‘so that the scarcity of copper-money does now occasion
frequent complaints.’
If the outstanding silver-money be reckoned at £60,000, the gold
at £30,000, and the copper at £60,000, the entire metallic money in
use in Scotland in 1707 would be under six hundred thousand
pounds sterling in value. It is not unworthy of observation, as an
illustration of the advance of wealth in the country since that time,
that a private gentlewoman died in 1841, with a nearly equal sum at
her account in the banks, besides other property to at least an equal
amount.
In March 1708, while the renovation of the coinage was going on,
the French fleet, with the Chevalier de St George on board, appeared
at the mouth of the Firth of Forth, designing to invade the country.
The Bank got a great alarm, for it ‘had a very large sum lying in the
mint in ingots,’ and a considerable sum of the old coin in its own
coffers, ‘besides a large sum in current species; all of which could not
have easily been carried off and concealed.’[392] The danger, however,
soon blew over. ‘Those in power at the time, fearing lest, all our
silver-money having been brought into our treasury, or into the
Bank, a little before, there should be a want of money for the
expenses of the war, ordered the forty- 1707.
shilling pieces to be again issued out of the
banks; of which sort of coin there was great plenty at that time in
Scotland, and commanded these to be distributed for pay to the
soldiers and other exigencies of the public; but when that
disturbance was settled, they ordered that kind of money also to be
brought into the bank; and on a computation being made, it was
found that the quantity of that kind, brought in the second time,
exceeded that which was brought in the first time [by] at least four
thousand pounds sterling.’[393]
We are told by the historian of the Bank, that ‘the whole nation
was most sensible of the great benefit that did redound from the
Bank’s undertaking and effectuating the recoinage, and in the
meantime keeping up an uninterrupted circulation of money.’ Its
good service was represented to the queen, considered by the Lords
of the Treasury and Barons of Exchequer, and reported on
favourably. ‘But her majesty’s death intervening, and a variety of
public affairs on that occasion and since occurring, the directors have
not found a convenient opportunity for prosecuting their just claim
on the government’s favour and reward for that seasonable and very
useful service.’