Fraunhofer Institute for Machine Tools and Forming Technology (IWU), Reichenhainer Str. 88, 09126 Chemnitz, Germany
Institute for Machine Tools and Production Processes (IWP), Technische Universitat Chemnitz, Reichenhainer Str. 70, 09126, Chemnitz, Germany
A R T I C L E I N F O
A B S T R A C T
Keywords:
Turning
Cryogenic machining
Polymer
Machining of elastomers offers more exibility of product shape in comparison to the common
compression moulding, especially for small batch series. In this context the entropy-elastic behaviour of
the material with low Youngs modulus is the main barrier for high-quality manufacturing. This material
behaviour could be temporarily adapted by cryogenic cooling for precise cutting. In this article, the
different mechanisms, e.g. forces, friction and separation procedures, are analysed for elastomers with
different material behaviours. Different chip formation mechanisms are shown in comparison to metal
machining. As a result, the friction (m 1) between work piece, chip and tool dominates. An analytic chip
formation model has been applied.
2016 CIRP.
(1)
Both moduli are inuenced by deformation rate and temperature. So G and G00 increase with increasing deformation rate. This
means that the elastomer becomes harder at higher deformation
rates and also dissipates more energy. Especially the reduction of
the operation temperature results in an increase of the moduli
(Fig. 1). Thus the material characteristic can be modelled.
http://dx.doi.org/10.1016/j.cirp.2016.04.075
0007-8506/ 2016 CIRP.
Please cite this article in press as: Putz (2) M, et al. Mechanism of Cutting Elastomers with Cryogenic Cooling. CIRP Annals Manufacturing Technology (2016), http://dx.doi.org/10.1016/j.cirp.2016.04.075
G Model
Fig. 3. Friction analysis under dry conditions - NBR ring on ground steel ring.
Fig. 4. Friction analysis under cryogenic conditionsNBR ring on ground steel ring.
Please cite this article in press as: Putz (2) M, et al. Mechanism of Cutting Elastomers with Cryogenic Cooling. CIRP Annals Manufacturing Technology (2016), http://dx.doi.org/10.1016/j.cirp.2016.04.075
G Model
Feed (mm)
Dry cutting
Cryogenic cooling
20; 40
20; 40
Fig. 6. Cutting and feed forces in dry and cryogenically cooled turning NBR with
different rake angles.
aB Ebf 3
2
Please cite this article in press as: Putz (2) M, et al. Mechanism of Cutting Elastomers with Cryogenic Cooling. CIRP Annals Manufacturing Technology (2016), http://dx.doi.org/10.1016/j.cirp.2016.04.075
G Model
based on the work of Vieregge [9], dealing with turning steel AISI
L6 (Rm = 800 MPa) with the cutting parameters vc = 100 m/min,
b = 4.25 mm and the tool parameters g = 108 and a = 58. The
comparison shows that power consumption of separation and
friction, which dominates elastomer machining, is smaller in steel
turning than the consumption of the deforming mechanism in the
shearing zone.
Especially for higher feeds or rather higher cutting crosssections, plastic material forming dominates the chip formation in
steel machining.
5. Conclusion
The machining of elastomers is based on mechanisms quite
different than those of steel. Especially the absence of plastic
deformation results in a different chip formation, including pure
separation in front of the cutting edge and friction of the chip on
the rake face. The low modulus of elasticity in dry turning results in
high deformation and low quality. Cryogenic cooling changes the
material properties and friction behaviour signicantly. As a result
the forces in the chip formation are increased, but the change of the
material behaviour from viscoelastic to energy-elastic with higher
Youngs modulus allows precise machining with improved chip
breaking.
Acknowledgements
The research results were obtained as part of the project
Technology for machining plastics assisted with cryogenic
cooling, which is funded by the Central Innovation Program for
SMEs (ZIM) of the Federal Ministry for Economic Affairs and Energy
based on a decision of the German Bundestag.
The authors wish to express their gratitude to their project
partners J. Schmalz GmbH and Metrom GmbH for their support.
References
Fig. 9. Chip formation of (a) cryogenically assisted turned elastomer and (b) dry
turned elastomer.
4. Summary
The analytic model of the force determination in combination
with the analysis of material and friction claries that machining of
elastomers is dominated by a separation process in front of the
cutting edge and relatively high power consumption due to the
friction of the chip on the tool rake face. In comparison to turning of
metals such as steel or aluminium, the power distribution is quite
different. Fig. 10 presents a qualitative comparison of the power
consumption distribution of the mechanism in chip formation in
turning of elastomers and steel. The values for steel turning are
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Please cite this article in press as: Putz (2) M, et al. Mechanism of Cutting Elastomers with Cryogenic Cooling. CIRP Annals Manufacturing Technology (2016), http://dx.doi.org/10.1016/j.cirp.2016.04.075