Influence of cutting process mechanics on surface integrity and electrochemical behavior of OFHC copper
TypeCommunications avec actes
Superfinishing machining has a particular impact on cutting mechanics, surface integrity and local electrochemical behavior. In fact, material removal during this process induces geometrical, mechanical and micro-structural modifications in the machined surface and sub-surface. However, a conventional 3D cutting process is still complex to study in terms of analytical/numerical modeling and experimental process monitoring. So, researchers are wondering if a less intricate configuration such as orthogonal cutting would be able to provide information about surface integrity as close as possible to that one generated by a 3D cutting process. For that reason, in the present paper, two different machining configurations were compared: face turning and orthogonal cutting. The work material is oxygen free high conductivity copper (OFHC) and the cutting tools are uncoated cemented carbide. The research work was performed in three steps. In the first step, the process mechanics of superfinishing machining of OFHC copper was performed. In the second step, the surface integrity and the chemical behavior of the machined samples were analyzed. Finally, in the third step, correlations between input parameters and output measures were conducted using statistical techniques. Results show that when applying low ratios between the uncut chip thickness and the cutting edge radius, the surface integrity and cutting energy are highly affected by the ploughing phenomenon. Otherwise, the most relevant cutting parameter is the feed. In order to compare face turning with orthogonal cutting, a new geometrical parameter was introduced, which has a strong effect in the electrochemical behavior of the machined surface.
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Orthogonal cutting simulation of OFHC copper using a new constitutive model considering the state of stress and the microstructure effects DENGUIR, Lamice; OUTEIRO, José; FROMENTIN, Guillaume; VIGNAL, Vincent; BESNARD, Rémy (Elsevier, 2016)This work aims to develop an orthogonal cutting model for surface integrity prediction, which incorporates a new constitutive model of Oxygen Free High Conductivity (OFHC) copper. It accounts for the effects of the state ...
DENGUIR, Lamice; OUTEIRO, José; FROMENTIN, Guillaume; VIGNAL, Vincent; BESNARD, Rémy (Elsevier, 2017)Due to the rising interest in predicting machined surface integrity and sustainability, various models for metal cutting simulation have been developed. However, their accuracy depends deeply on the physical description ...
Friction Model for Tool/Work Material Contact Applied to Surface Integrity Prediction in Orthogonal Cutting Simulation DENGUIR, Lamice; OUTEIRO, José; RECH, J.; FROMENTIN, Guillaume; VIGNAL, V.; BESNARD, R. (Elsevier, 2017)Tribological behavior at both tool/chip and tool/work material interfaces should be highly considered while simulating the machining process. In fact, it is no longer accurate to suppose one independent constant friction ...
Experimental and numerical assessment of subsurface plastic deformation induced by OFHC copper machining OUTEIRO, José; CAMPOCASSO, Sébastien; DENGUIR, Lamice; FROMENTIN, Guillaume; VIGNAL, Vincent; POULACHON, Gérard (Elsevier, 2015)Strain distributions in the machined surface and subsurface of OFHC copper workpieces were determined experimentally and through numerical simulations. An experimental setup, comprising a double frame camera and a pulsed ...
Flank wear prediction in milling AISI 4140 based on cutting forces PCA for different cutting edge preparations DENGUIR, Lamice; BESNARD, Aurélien; FROMENTIN, Guillaume; POULACHON, Gérard; ZHU, Xiaowen (Inderscience, 2016)One of the criteria mastering the choice of a cutting tool is its wear resistance. For coated inserts, prior to the coating process, edge preparation method choice will impact their performance. So, a classification based ...