PSI - Issue 53

A. Teixeira et al. / Procedia Structural Integrity 53 (2024) 352–366 Author name / Structural Integrity Procedia 00 (2019) 000–000

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negative 80º rhombic shape and a cutting edge of 0.2 mm of radius. Cutting insert geometry and dimensions are displayed in Fig. 2.

Fig. 2. Geometry and dimensions of the used turning insert, CNMG 120402-GSF.

2.2. Experimental setup The workpiece material cylindrical test specimens were machined on a MAZAK INTEGREX i-200ST multi tasking CNC machine. Cutting force measurements were performed using a Kistler 9129A piezoelectric dynamometer and a Kistler 5070A signal amplifier. The signal from the charge amplifier was then collected by a data acquisition system (Kistler 5697A) and Kistler Dynoware software which allowed signal conversion and data collection. A sampling rate of 1000 Hz was defined for the 3 three components Fx, Fy and Fz, which correspond to the passive, cutting and feed force, respectively. The schematic representation of the experimental setup is shown in Fig. 3(b).

Fig. 3. Experimental setup diagram: (a) tool holder and effective rake, clearance and cutting-edge angles; cutting tool and tool holder relative position to the workpiece and load-cell, (b) close-up of the force acquisition system and its components.

A tool holder (ISO DCLNL 2525M 12) was clamped to the dynamometer resulting in an insert (ISO CNGA 120408) setting angle of 95°, resulting in a rake angle of -6.5 and clearance angle of 6.5°. Concerning lubrication conditions, soluble oil emulsion was used with a pressure of 3.7 bar pointed towards the cutting edge. Tested levels of each cutting parameter are presented in Table 2.

Table 2. Turning test cutting parameters. a p (mm) f (mm/rev) v c (m/min)

0.1

50

100 150

0.2

0.2