Definition of the microtopography of surfaces in thermal contact (2023)

A new approach based on the combination of wavelet and fractal theories is proposed. The purpose is to provide a mechanism to more accurately and completely evaluate the properties of engineered surfaces. Wavelet transformation models and fractal representations of technical surfaces are presented and the combination of wavelet models and fractal representations is examined. With the proposed approach, experimental samples of the workpiece surface obtained by grinding are examined. The results show that the proposed approach is correct and complete.

Friction models for piston rings and other machine elements often include the Greenwood and Tripp contact model and the Patir and Cheng average flow model for the mixed lubrication mode. However, problems arise from the non-Gaussian roughness height distributions of cylinder liners and from the unsteadiness of the surface roughness parameters used in these models. This article shows how to solve these problems. From this it is concluded that the upper part of the coating roughness height profile has a Gaussian distribution and this is used to determine the appropriate roughness height for use in the friction model. The non-stationarity is solved using the plasticity criterion proposed by T R Thomas. This idea has not received much attention in the literature and experimental support is still lacking. In this work, an experimental validation is provided and it is concluded that both the use of the proposed solution for the non-Gaussian liner roughness and the application of the Thomas plasticity criterion allow an accurate prediction of the piston ring friction.

Computer Aided Design, Band 50, 2014, S. 16-26

The performance of ball end mills in cutting operations is affected by the configuration of the rake and flank faces on the spherical component. From the mathematical design of a cutting edge curve, the rake face can be defined by the rake angle and rake width at each cross-section along the cutting edge. We propose the basic conditions that should govern the coupling between the grinding wheel and the release surface in order to avoid interference during the processing of a ball mill. As a result, a new mathematical model for determining the position of the wheel and a software program for simulating the generation of the contact surface of a ball mill are proposed. In addition, methods for grinding the flank in both concave and planar forms are presented. The groove area created by a disc during the grinding process is determined using a tangent condition. The results of the experiment and the simulation are compared to validate the proposed model.

Wear, Vol. 317, Numbers 1–2, 2014, pp. 8-16

This article examines the friction of bevel cutting in bevel Si turning.₃norte₄Ceramic tools with a large negative rake angle. The flank friction in particular is included in the tribological equilibrium. The values ​​of the force components recorded during the tool wear tests at different cutting speeds served as input data. The usual force components were transformed into the coordinate system of the tool used in order to be able to calculate the normal and frictional forces acting on the rake and flank surfaces and finally the corresponding friction coefficients. It was found that both friction coefficients change significantly with progressive tool wear and deviate from those determined for the orthogonal friction model. The new friction pattern was tested for machining ductile iron (SCI) with coated nitride ceramic inserts and further validated by tribo testing using cylinder-on-disk methods.

International Magazine of Machine Tools and Manufacturing, Band 105, 2016, S. 32-44

In this article, a new and innovative method for regular structuring and special modeling of the workpiece surface using face milling is presented. The patterns were created on the surface by specific positioning of the workpiece and tool, milling passes in different directions, and the specific angular position of the spindle on a typical vertical milling machine. First, the model for the geometry of the cutting tool was developed and then a new simulation model for the surface pattern was created through the face milling process. Mathematical models are presented to describe the geometry and position of the cutting tool (including orientation and position) in space. Calculation and simulation programs (MATLAB and CAD programming software) are developed to verify this method. This study provides a basic understanding of the pattern milling process. Based on this, the influence of various milling process parameters on the pattern geometry (including the lead-in angle and radius) is analyzed. The simulation results could be used to optimize the traditional milling and pattern milling processes, as well as to improve the surface quality of the workpiece or to predict the surface pattern based on given face milling parameters.

Materials Today: Proceedings, Band 5, Nummer 2, Teil 2, 2018, S. 7037-7046

Temperature measurement and estimation of heat distribution in metal cutting is important as it controls the contribution to tool deflection, tool life, cutting force and vibration, and the quality of the machined part. In this paper, a statistical model was developed to estimate the temperature rise using design parameters such as helix angle, radial inclination angle of the cutting tool, and machining parameters such as cutting speed, cutting speed, etc., feed and axial depth of cut in dry conditions. Reaction surface methodology and experimental design were used to conduct the experiments. The workpiece material was 7068 Al aluminum and the tool was a high speed steel end mill with a different tool geometry. The temperature rise was evaluated with a pyrometer. The second-order mathematical model related to machining parameters was developed to estimate temperature rise. The competence of the model was calculated using ANOVA. The direct and interacting effect of the process parameter on the temperature rise was analysed, which helped to select the process parameter to keep the temperature rise to a minimum, indicating the immobility of the final milling process. The prediction models in this study are believed to produce temperature rise values ​​that are close to the experimentally recorded readings with a 95% confidence interval. A Matlab genetic algorithm solver was used to perform the optimization.

Measure, Band 132, 2019, S. 68-78

The current challenge in the manufacturing industry is to improve the efficiency of production activities while reducing wasteful energy consumption. Previous research has focused on optimizing multiple responses of process parameters to improve process performance. The present study proposed an optimization-based strategy to reduce energy consumption in end milling with D2 steel microspheres. Since power consumption is directly proportional to cutting forces, process parameters such as cutting speed, feed rate and depth of cut were optimized to reduce cutting forces using the Gauge-Based Optimization Technique (TLBO) along with 3D Finite Element Method (FEM) simulation. During the optimization, limit values ​​of 60 µm (ISO 10816) and 2 µm (ISO 1302) were assumed for the vibration amplitude of the milling cutter and the surface roughness. The three best combinations of cutting speed, feed and depth of cut for minimum cutting force were determined. Among other things, the combination of a cutting speed of 15 m/min, a feed of 112.5 µm/tooth and a cutting depth of 85.25 µm has a low power consumption of 67 W with a tool vibration of 36.5 µm. However, the remaining two combinations were also considered to be the next best optimal cutting conditions. For the three best solutions, a numerical simulation was carried out and the cutting forces and the amplitude of the vibration of the milling cutter were predicted. There was good agreement between the simulation results and the experimental results, confirming the acceptability of the simulation. It was also found that the three best candidate solutions had the same cutting speed of 15 m/min (minimum cutting speed). Therefore, it was found that the induced stresses in the workpiece have low values ​​around 350 MPa.

International Magazine of Machine Tools and Manufacturing, Bände 130–131, 2018, S. 49-64

Since it is known that chip geometry helps to predict machining forces, energy and thus the quality of the machined surface, several models have been developed in the past to predict deformed and undeformed chip geometries in spherical milling. It can be observed that most models use the volume constancy (VC) between the undeformed and deformed chip geometry to evaluate the deformed chip thickness. This work presents a new approach to assess deformed chip geometry, which includes considering deformations in deformed chips (SDC). In the strains developed using the deformed chip (SDC) approach, bending, compression/shear, and thermal strains were modeled using a simplified shape of a conical overhang of the undeformed chip. When developing the model, the interactions between the cutting edge and machining on horizontal work surfaces and those inclined at different angles were taken into account. As the slope of the workpiece increases from 0° (horizontal) to 60°^°, deformed chip thickness increases by 63% due to greater effective feed per tooth. However, it was found that the instantaneous shear angle is constant at 50°^°along the cut for a typical parametric machining combination. A comparison of the SDC and VC approaches shows that the magnitudes of deformed chip thickness, rake angle and resulting cutting forces obtained from SDC models are the closest (within 90%) in agreement with experimental data. It is expected that such models, when integrated with shear force models, would help predict shear forces more accurately.