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1. Understanding of Residual Stress and Subsurface Damage by 2- Step Machining of Single Crystal Sapphire

   Nagaraj, Aditya ; Min, Sangkee ( December 2022 , 19th International Conference on Precision Engineering)

   The Japan Society for Precision Engineering (Ed.)

   Machining is in general conducted in multiple paths and thus residual stress and subsurface damage formed by previous cut may influence subsequent cutting. Ceramics materials are extremely brittle and prone to cracks. Ultra-precision machining with very small depth of cut enables ductile mode cutting. There have been various reports that critical depth of cut (CDC) for single crystal sapphire exists, where the ductile to brittle transition occurs. However, the CDC of subsequent cutting changes due to the influence of residual stress and subsurface damage by previous cut. This study investigates the indirect effect of residual stress and subsurface damage on the critical depth of cut of the second cut by analyzing the plastic deformation mechanisms activated during 2-step machining on A-plane of sapphire. It was found that the [1#100] machining orientation was most suitable since the critical depth of cut remained fairly constant due to dominant rhombohedral twinning activation during subsequent machining operations. 

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2. Tool wear area estimation through in-process edge force coefficient in trochoidal milling of Inconel 718

   Shah A. ; Agarwal A. ; Mears L. ( January 2023 , Manufacturing letters)

   The rapid wear and premature failure of the cutting tool are prone to happen due to increased forces during machining difficult-to-cut materials such as Inconel 718. The application of alternative toolpath such as trochoidal milling has significantly improved tool life and reduced the overall cycle time of the process. The wear pattern of the tool has a direct impact on the cutting forces, which increases with tool deterioration. The cutting forces in milling are modeled through the mechanistic force model and can be designated through a set of force coefficients, i.e. cutting and edge representing the shearing and ploughing phenomenon of metal removal. It has been established in the literature that tool wear has a considerable effect on the value of edge force coefficients. This paper aims to determine the in-process edge force coefficients for the trochoidal toolpath and correlates them with the corresponding flank wear area. The proposed correlation will further assist in predicting the level of flank wear area based on the force values in trochoidal milling. 

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3. Trochoidal milling: investigation of dynamic stability and time domain simulation in an alternative path planning strategy

   https://doi.org/10.1007/s00170-018-03280-y  

   Akhavan Niaki, F ; Pleta, A ; Mears, L ; Potthoff, N ; Bergmann, Jim A ; Wiederkehr, P ( July 2019 , International journal, advanced manufacturing technology)

   Trochoidal milling is an alternative path planning strategy with the potential of increasing material removal rate per unit of tool wear and therefore productivity cost while reducing cutting energy and improving tool performance. These characteristics in addition to low radial immersion of the tool make trochoidal milling a desirable tool path in machining difficult-to-cut alloys such as nickel-based superalloys. The objective of this work is to study the dynamic stability of trochoidal milling and investigate the interaction of tool path parameters with stability behavior when machining IN718 superalloy. While there exist a few published works on dynamics of circular milling (an approximated tool path for trochoidal milling), this work addresses the dynamics of the actual trochoidal tool path. First, the chip geometry quantification strategy is explained, then the chatter characteristic equation in trochoidal milling is formulated, and chatter stability lobes are generated. It is shown that unlike a conventional end-milling operation where the geometry of chips remains constant during the cut (resulting in a single chatter diagram representing the stability region), trochoidal milling chatter diagrams evolve in time with the change in geometry (plus cutter entering and exiting angles) of each chip. The limit of the critical depth of cut is compared with conventional end milling and shown that the depth of cut can be increased up to ten times while preserving stability. Finally, the displacement response of the cutting tool is simulated in the time domain for stable and unstable cutting regions; numerical simulation and theoretical results are compared. 

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4. Generalized mechanics and dynamics of modulated turning

   https://doi.org/10.1016/j.jmatprotec.2022.117708  

   Eren, Bora ; Nam, Soohyun ; Sencer, Burak ( October 2022 , Journal of materials processing technology)

   Budak, Erhan (Ed.)

   This paper presents a generalized cutting force and regenerative chatter stability prediction for the modulated turning (MT) process. Uncut chip thickness is modeled by considering current tool kinematics and undulated (previously generated) surface topography for any given modulation condition in the feed direction. It is found that chip formation is governed by the undulated surface generated in multiple past spindle rotations. Uncut chip thickness is computed analytically in the form of trigonometric functions, and cutting forces are predicted by making use of orthogonal cutting mechanics. Regenerative chatter stability of the process is also modelled. Analytical semi-discretization-based solution is developed to accurately predict the stability lobe diagrams (SLDs) of the MT process. Predicted stability lobes are validated through numerical time-domain simulations and experimentally via orthogonal (plunge) turning tests. It is found that as compared to conventional single-point continuous turning, regenerative stability of MT exhibits multiple (3) regenerative delay loops and long out-of-cut duration in-between tool engagement stabilizes the process to reach up to 2x higher stable widths/depths as compared to the conventional continuous turning. 

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5. Polyacrylamide hydrogels. III. Lap shear and peel

   https://doi.org/10.1016/j.jmps.2021.104348  

   Wang, Yecheng ; Yin, Tenghao ; Suo, Zhigang ( May 2021 , Journal of the Mechanics and Physics of Solids)

   Lap shear and peel are common tests for soft materials. Their results, however, are rarely compared. Here we compare lap shear and peel as tests for measuring toughness. We prepare specimens for both tests by using stiff layers to sandwich a layer of a polyacrylamide hydrogel. We introduce a cut in the hydrogel by scissors, pull one stiff layer at constant velocity, and record the force. In lap shear, the force peaks and then drops to zero, the cut grows unstably through the entire hydrogel, and the peak force is used to determine toughness. In peel, the force peaks and then drops to a plateau, the cut grows in the hydrogel in steady state, and the plateau force is used to determine toughness. Our experimental data show that the average values of toughness determined by lap shear and peel are comparable. The peak forces in both tests scatter significantly, but the plateau force in peel scatters narrowly. Consequently, toughness determined by lap shear scatters more than toughness determined by peel. We hypothesize that the peak forces scatter mainly due to the statistical variation of the cuts made by scissors, and test the hypothesis using two additional sets of experiments. First, after a cut is made by scissors, we pre-peel the specimen to extend the cut somewhat, and then measure toughness by lap shear and peel. The peak force in lap shear scatters less, and the peak force in peel is removed. Second, we prepare cuts using spacers of various thicknesses, and find that the peak forces in both lap shear and peel vary with the thickness of the spacer. These findings clarify the use of lap shear and peel to characterize soft materials. 

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