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Modeling of process forces with consideration of tool wear for machining of sintered steel alloy for application to valve seat in a combustion engine

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Abstract

The reliable and precise machining of cylinder head components in the combustion engine represents a crucial and complicated step in the production process. In industrial manufacturing processes, disturbances are inevitable and provide a measure of uncertainty in each production step. Increasingly, the influence of such uncertainties is being evaluated using simulation models. To determine the performance quality of the model, a suitable cutting material and the edge geometry must be identified. In this paper, experimental investigation of polycrystalline cubic boron nitride grades for machining valve seats made of powder metallurgy steel in a combustion engine is presented. Then, a mechanistic approach is used to establish a prediction model of the process forces based on the experimentally determined data set.

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Abbreviations

A:

Cross-secion of undeformed chip (mm2)

ap :

Depth of cut (mm)

b:

Width of undeformed chip (mm)

f:

Feed per rev. (mm/rev)

Fc :

Cutting force (N)

Ff :

Feed force (N)

Fp :

Passive force (N)

Fr :

Radial force (N)

Kc :

Specific cutting force (N/mm2)

Kf :

Specific feed force (N/mm2)

Kp :

Specific passive force (N/mm2)

t:

Time (s)

V:

Material removal volume (cm3)

VB:

Width of flank wear-land (μm)

vc :

Cutting speed (m/min)

β:

Regression coefficient (-)

γ:

Working rake angle (°)

κ:

Tool edge angle (°)

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Acknowledgements

The authors would like to thank the German Research Foundation (DFG) for funding the research activities at the Collaborative Research Centre (CRC) 805 Control of Uncertainty in Load-Carrying Structures in Mechanical Engineering. Tools were supplied by Kennametal within the framework of the project.

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Authors and Affiliations

  1. Institute of Production Management, Technology and Machine Tools (PTW), Otto-Berndt-Str. 2, 64287, Darmstadt, Germany

    C. Bölling, M. Kuhne & E. Abele

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  1. C. Bölling
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  2. M. Kuhne
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  3. E. Abele
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Correspondence to C. Bölling.

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Bölling, C., Kuhne, M. & Abele, E. Modeling of process forces with consideration of tool wear for machining of sintered steel alloy for application to valve seat in a combustion engine. Prod. Eng. Res. Devel. 11, 477–485 (2017). https://doi.org/10.1007/s11740-017-0759-y

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