Kordestany & Ma, Cogent Engineering (2017), 4: 1412106

https://doi.org/10.1080/23311916.2017.1412106

PRODUCTION & MANUFACTURING | RESEARCH ARTICLE

Force calculation using analytical and CAE methods
for thin-blade slotting process
Yazdan Kordestany1 and Yongsheng Ma1*

Received: 27 July 2017 Abstract: A multi-spindle slotting process is taken as the case to analyse the
Accepted: 28 November 2017
mechanism involved in the cutting process affecting the machining efficiency. The
First Published: 02 December 2017
analysis techniques used in this research include force analysis through existing
*Corresponding author: Yongsheng Ma,
Mechanical Engineering Department, analytical and numerical models and implementing the results to conduct an in-
University of Alberta, #10-235 Donadeo depth analysis of the cutting dynamics. The input parameters considered are blade
ICE Building, Edmonton, Alberta, AB T5G
1H9, Canada geometry, cutting speed, and feed rate to investigate their effects on tool life. The
E-mail: [email protected]
study of dynamics of the cutting process was also extended to determine the effect
Reviewing editor: of chatter vibration by determining the stability lobe diagram of the process. Results
Chaoqun Wu, Wuhan University of
Science and Technology, China coupled from these two primary parts of the investigation were used to identify
Additional information is available at
optimal processing conditions. The approaches employed to specify conditions for
the end of the article the stability lobe diagram showed that the method can be applied to analyse dif-
ferent combinations of tool and workpiece materials. Finite element methods along
with the obtained force are then applied to simulate the static force distribution for
a circular saw blade. The determined blade deformation and a CAD/CAE software
are used for the optimization process. Finally, it is possible to compare the resulting
deformations for both optimized and original blade geometries.

ABOUT THE AUTHORS PUBLIC INTEREST STATEMENT

Yazdan Kordestany completed his MSc study A great number of formed products that are dealt
under supervision of Prof Ma from University with in engineering undergo machining processes
of Alberta in 2017. His research project was (turning, milling, drilling, sawing) to remove
characterization and optimization of multi-spindle unwanted material from blank using a tool that
slotted liner manufacturing process dealing with has a harder material than final products. All
prevailing setbacks including short tool life due to manufacturers concern about reducing their cost
vibration. He had sound experience conducting by justifying economical machining processes. Tool
comprehensive solid modelling and engineering life plays an important role in manufacturing’s
analysis across a variety of CAD and CAM cost which is determined by factors such as
applications towards optimizing manufacturing rotational speed of tools, linear movement of the
processes. tool/workpiece, tools’ geometry. Slotted liners
Yongsheng Ma is a full professor with the are pipes with small openings on their surface
Faculty of Engineering, University of Alberta. used in unconventional oil extraction as a sand
He joined University of Alberta since 2007. Dr control device. This article studies on a thin blade
Ma is a member of ASEE, SME, and an Alberta slotting process customized on a multi-spindle
registered Professional Engineer. His main machine used to manufacture slotted liners. The
research areas include feature-based design and main purpose was to identify machine parameters
manufacturing modeling, CADCAM, and product and tool geometry by developing mathematical
lifecycle management. Dr Ma received his BEng and numerical model to reduce the machining
from Tsinghua University, Beijing (1986), both MSc vibration, tool breakage, and the number of times
(1990) and PhD (1994) from UMIST, UK. Dr Ma needed for tool sharpening.
had been an associate editor of IEEE Transaction
of Automation Science and Engineering (2009–
2013). Since 2012, he has served as an editor of
Advanced Engineering Informatics (Elsevier).

© 2017 The Author(s). This open access article is distributed under a Creative Commons Attribution
(CC-BY) 4.0 license.

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Subjects: Structural Mechanical Engineering; Manufacturing Engineering Design;

­Engineering Productivity

Keywords: slotting process; thin circular blade; chatter vibration; orthogonal cutting;
­cutting force; CAD/CAE; finite element analysis

1. Introduction
Close to a third of the crude oil Canada produced from oil sands used Steam assisted gravity drain-
age (SAGD) (Holly, Mader, Soni, & Toor, 2016) to extract oil from oil sand reserves. Sand control
methods such as slotted liner are, therefore, necessary to avoid passing of solids through the open
area to flow allowed for oil production. Slotted liners for sand control in SAGD typically include a pipe
casing on which rectangular apertures (slots) are made by methods such as cutting with circular saw
blades. These slots will provide the required open area to steam injection and oil production while
preventing sand particles to enter the pipe. Slotted liners have been extensively used as sand control
device in SAGD applications due to their mechanical integrity for long horizontal well completions
(Matanovic, Cikes, & Moslavac, 2012).

Circular saw blades can be used as a tool to manufacture slotted liners in slotting machines similar
to numeric control (NC) milling machines. There are several industries that apply multi spindle NC
machines to produce slotted liners. Since each pipe joint has hundreds of slots, this approach has the
advantage of reducing production time and cost by having multi spindles that it allows simultane-
ous cutting of slots.

The slotting machine considered in this study has been designed and built in-house. Since it was
custom made, this research aims at obtaining a comprehensive description of the manufacturing
process with respect to interacting performance parameters. The following are the major objectives
set for this study as conduct force analysis on the blades to determine the distribution of forces and
perform dynamic stability analysis to obtain a stability lobe diagram to determine combinations of
feed rate and spindle speed values that are in stable zones. Finally, the geometry of thin blade can
be optimized with regard to static force analysis to reduce the tool deflection.

In the slotting process, the mechanics on each tooth on the circular saw blade follows orthogonal
cutting theory since the cutting edge of each tooth is parallel to the surface of the workpiece and
perpendicular to the cutting orientation (Balihodzic, 2002). The material removal process is also
considered to be distributed along the cutting edge. It is thus a two dimensional plane strain prob-
lem (Kiliçaslan, 2009).

2. Theory
Direct experimental techniques used to study cutting processes are usually costly and time consum-
ing. Therefore, analytical and numerical approaches may appeal the researcher. It should, however,
be noted that the mechanics of machining cannot be fully explained by using only analytical ap-
proaches. This is the main reason behind the application of numerical methods such as finite ele-
ment analysis in conjunction with analytical models.

In the shear plane model from the theory of Ernst and Merchant (1941), shear forms the chip
along a single plane inclined at an angle ϕ. The shear stress along the shear plane is equal to the
material flow stress in shear. The chip is assumed a separate body in static equilibrium as shown in
Merchant’s circle force diagram given in Figure 1. Merchant derived equations for cutting and thrust
forces showing their dependence on the shear angle (angle between shear plane and cutting sur-
face). All forces act at the tool tip. The forces applied to the chip come from two parts: the tooth, and
the uncut workpiece. The balance of these forces results in the force equilibrium.

Ernst and Merchant’s theory is based on minimum cutting energy principle to reduce the cutting
work to a minimum. Since the main factor is cutting force, two steps should be involved in the

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Figure 1. Merchant’s circle force

diagram.

analysis. Establishing the relationship between cutting force and shear angle should be done first
followed by identifying the shear angle to keep the cutting force at the minimum. From Figure 1 it
can be seen that:

Fs = Fc cos(𝜙 + 𝛽 − 𝛼) (1)

wh
Fs = 𝜏s As = 𝜏s (2)
sin𝜙
where, 𝜏s is the shear stress, Asis the shear plane area, w is the width of cut, and h is the uncut chip
thickness.

From Equations (1) and (2):

wh 1
Fc = 𝜏s × (3)
sin𝜙 cos(𝜙 + 𝛽 − 𝛼)
The tangential and feed forces can then be written as:

wh cos (𝛽 − 𝛼)
Ft = Fc cos (𝛽 − 𝛼) = 𝜏s × (4)
sin𝜙 cos(𝜙 + 𝛽 − 𝛼)

wh sin (𝛽 − 𝛼)
Ff = Fc sin (𝛽 − 𝛼) = 𝜏s × (5)
sin𝜙 cos(𝜙 + 𝛽 − 𝛼)
The first step in this study is calculation of applied force in the slotting process. Having determined
the maximum number of teeth that are in touch with the workpiece during cutting and the
corresponding depth of cut, the applied force can be obtained from finite element simulations. The
­

mechanics of machining cannot be fully explained by using only analytical approaches. Therefore,
numerical approaches in metal cutting processes have been interesting to researchers using various
available explicit and implicit software packages such as ABAQUS, ANSYS, AdvantEdge and etc. For
instance, Reiter and Keltie (1976) adapted a rigid-plastic finite element model with an Eulerian
­formulation to simulate steady-state orthogonal metal cutting. Komvopoulos and Erpenbeck (1991)
applied constitutive material behavior models and interfacial friction mechanisms representing real
application scenarios for metal cutting simulation of AISI 4340 steel with ceramic-coated tools to
investigate the effect of cutting parameters. The effect of tool edge geometry was also studied by
Wan, Wang, and Gao (2015) in orthogonal metal cutting by adoption of arbitrary
Lagrangian-Eulerian (ALE) approach for simulation in ABAQUS/Explicit and considering P20 as the
workpiece material.

The physical separation criteria are based on value of physical properties, such as stress, strain, or
strain energy in the elements or nodes immediately ahead of the tool tip. The critical values of the

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nodes’ physical quantities are used to estimate the separation and the nodes separate, when the
magnitude of the controlled variable in an element is larger than the critical value. Johnson-Cook
plasticity and damage model with element deletion technique is gaining popularity to be often ap-
plied as separation criteria to finite element simulation of cutting (e.g. Agmell, Ahadi, & Ståhl, 2013;
Escamilla, Zapata, Gonzalez, Gámez, & Guerrero, 2010; Liu, Wang, Li, & Deng, 2013; Sawarkar &
Boob, 2014; Wang & Liu, 2014; Zhang, Outeiro, & Mabrouki, 2015). It considers the separated effects
of strain hardening, strain-rate (viscosity) and thermal softening. It is a relatively simple model and
defines the general response of material deformation (Zhang et al., 2015).

3. Methodology
In view of the reviewed relative theories, the methodology of this study can be summarized in Figure
2. After defining the problem as orthogonal cutting process, the cutting parameters along with ge-
ometries and material properties of both workpiece and pipe are used as input variables. All input
parameters are applied in both numerical and analytical studies. The results from both methods are
used for dynamic stability analysis and shape optimization. Finally, the overall results are the opti-
mal values of blade geometries for an improved operation.

The coordinate system should be defined first so that the key time points can be described and
each tooth can be positioned at a given time point. Some parameters such as angle per tooth are
measured with reference to the centre of the circular saw blade, while others such as the feed rate
are measured based on the space transformation of the circular saw blade. Therefore, a single type
of coordinate system cannot express all these parameters simultaneously. Two types of coordinate
system, namely global coordinate system and local coordinate system are employed in this study.

As shown in Figure 3, the downward direction is set as the positive x-axis and the rightward direc-
tion as the positive y-axis for the global coordinate system. An important feature to note here is that
this coordinate system moves with time, i.e. the absolute physical position of the circular saw blade
keeps changing during the slotting process.

Figure 3 shows the starting moment (t = 0) of the slotting process.

Figure 2. Summary of the

methodology.

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Figure 3. Schematic of global

and local coordinate system.

When analysing the forces applied to the single tooth, the local coordinate system defined in
Figure 3 is used. The x-axis is along the cutting direction (tangential direction of the outer circle) and
the y-axis is the radial direction pointing to the centre of the circular saw blade. Likewise, this coor-
dinate system is also dynamic, i.e. the origin of this local coordinate system keeps changing with
time.

Figure 4(a) shows the starting position of the blade with a federate of vf1. The first touching time
of outer circle can be calculated as:

2(H − R)
t0 = (6)
vf1 + vf2
Generally, the first touching time of teeth is different from that of the outer circle, i.e. t1 ≠ t0, be-
cause there is not always one tooth that touches the workpiece when the outer circle just reaches
2(H−R)
the workpiece. Only when t0 = = m.Ttooth (where m is an integer and Ttooth is the time in sec-
vf1 +vf2
onds taken by one tooth to travel to the position of its adjacent front tooth), that t1 = t0 holds.
Otherwise, t1 > t0, i.e., at this condition, the tooth touches the workpiece for the first time at the left
hand side (LHS) of the positive x-axis. Figure 4(b) shows the locations of the circular saw blade at
time t0 and t1, respectively, with Points O and O’ as the corresponding centers of the circle. It is obvi-
ous that the time period (t1 − t0) is less than Ttooth. At time t0, this immediate tooth on the LHS is at
P1and the outer circle of the circular saw blade just touches the workpiece at P3 Figure 4(c). At time
t1, the circular saw blade moves and the immediate LHS tooth of the positive x-axis travels from P1
to P2. At this time point, this immediate LHS tooth just touches the workpiece at P2. During this time
period (t1 − t0), the center of the circle travels a distance of vf2 (t1 − t0). Drawing a perpendicular line
from P2 to the x-axis shows the perpendicular foot to be atP3. The angles 𝜃0and 𝜃0 define the radial
′

angles of this immediate LHS tooth at time t0 and t1, respectively.

When the circular saw blade cuts through the workpiece, the center of the circular saw blade
travels a distance equal to Th (pipe thickness)such that:

2Th
t2 = t1 + (7)
vf2 + vf3
when the circular saw blade completes cutting the workpiece, the targeted slot length is met,
Therefore,

Figure 4. Schematic of key time

points.

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2P (8)
t3 = t2 +
vf3 + vf4

where P is the plunge distance which is the distance between the deepest point of blade and inner
diameter of pipe when the blade reaches its deepest position.
√
( )2
2 L (9)
P=R− R −
2
where L is the slot length on the outer surface of the pipe.

The number of teeth involved in the slotting process at a transient time point is defined as the ef-
fective teeth which is a function of time shown in Figure 5.

The location of each tooth at a given time point can be denoted by 𝜃phase which is the global radial
angle of each tooth in reference to the positive x-axis. Its value can be calculated as:

⎧ 𝜃 (n, t) = 2𝜋n + 𝜔t
⎪ im N
⎨ where n is index of teeth, (10)
⎪ where t is index of time,
⎩
Two components of the resultant force, tangential (Ft) in x direction and feed (Ff) forces in y direc-
′ ′

tion, can be expressed (Altintas, 2012), respectively as:

Ft = Fc cos(𝛽 − 𝛼) (11)

Ff = Fc sin(𝛽 − 𝛼) (12)

The tangential and feed forces can also be given as:

( )
2𝜋 v f (t) sin 𝜃ju. (n, t)
(13)
Ft = Kt
𝜔N
( )
2𝜋 v f (t) sin 𝜃ju. (n, t)
(14)
Ff = Kf
𝜔N
where, Kt and Kf are tangential and feed cutting force coefficients, respectively and are equal to
(Altintas, 2012):

𝜏s W cos(𝛽 − 𝛼)
Kt = (15)
sin𝜙 cos (𝜙 + 𝛽 − 𝛼)

𝜏s W sin(𝛽 − 𝛼)
Kf = (16)
sin𝜙 cos (𝜙 + 𝛽 − 𝛼)

Figure 5. Effective teeth.

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Since the slotting machine has eighty spindles, the overall force applied to the machine during the
cutting of one slot can be calculated as the sum of the resultant forces applied to all blades. However,
there is a phase difference between spindles in reality. Therefore, the summation of forces has to
take the phase difference in rotation of all the blades into account of.

To obtain a mathematical solution for the forces as per the above series of discussion, input data
that correspond to the specific properties and geometries of the workpiece and tool were used along
with the machine parameters in the MATLAB algorithm as shown in the Figure 6. Friction angle,
shear angle, and shear stress values are typically obtained from empirical investigations. The litera-
ture and small-scale numerical simulations were thus used to determine the values of these three
parameters.

Figure 6. Force calculation

algorithm.

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Lagrangian approach was used in ABAQUS/Explicit in 3D model to idealize the chip formation as
the mesh nodes are moving with the material movement. The Lagrangian model included the ele-
ment deletion as the failure criteria to remove chip from the workpiece. The element type used in
ABAQUS was eight-node linear brick with reduced integration and hourglass control.

Simulation of cutting processes is complex due to large plastic deformation and material removal
at large strain rates and high temperatures (Kershah, 2013). Johnson-Cook material model is one of
the commonly used orthogonal cutting models, since it depends on strain rate and temperature. The
Johnson-Cook martial model which is used in this study can be represented as:

( ( ))( ( ) )
( n
) 𝜀̇ T − Tr m
𝜎 = A + B𝜀 1 + C ln 1− (17)
𝜀̇ 0 Tm − T r

where, 𝜎 is the equivalent stress, A is the initial plastic flow stress at zero plastic strain, B is the strain
hardening coefficient, n is the strain-hardening index, C is the strain rate index, 𝜀 is the plastic strain,
𝜀̇ is the plastic strain rate, 𝜀̇ 0 is the reference plastic strain rate, T is the current temperature, Tr is the
reference temperature, Tm is the melting temperature, and m is the thermal softening index. These
values are usually obtained from Split Hopkinson Pressure Bar (SHPB) impact testing data (Shih,
1995).

Johnson-Cook damage law was used for chip separation in this study as given by (Agmell et al.,
2013):
( )
∑ Δ𝜀
D= (18)
𝜀f

where, D is the damage parameter, Δ𝜀 is the increment of the equivalent elastic strain which is up-
dated at every load step, and is the equivalent strain at failure and can be expressed as (Agmell et
al., 2013):

[ ( )][ ( )][ ( )]
P 𝜀̇ T − Tr
𝜀f = D1 + D2 exp D3 1 + D4 ln 1 + D5 (19)
𝜎 𝜀̇ 0 Tm − Tr
P
where, is the ratio of hydrostatic pressure to equivalent stress. When D (damage parameter) of an
𝜎
element reaches 0.1, the failure occurs and the FEM algorithm deletes the element. The L-80 alloy
steel pipe is selected for this study as a workpiece which has a similar chemical composition and
properties to AISI 4140. The Johnson-Cook plasticity model parameters, damage parameters, and
general thermal and mechanical properties of the workpieces obtained from literature having the
Young’s modulus and Poisson’s ratio as 219 × 109 N/m2 and 0.29, respectively (Agmell et al., 2013;
Johnson & Cook, 1985). Since the elastic modulus of cutting tools are usually higher than those of
−3
the workpieces, rigid elastic cutting tool was assumed with the density of 8,160 kgm , Young’s
modulus 214 × 10  N/m , and 0.3 Poisson ratio to reduce the computational cost.
9 2

Sticking and sliding are two zones that contact interactions between tool and workpiece occur in.
Both normal and shear forces are transmitted for the cases where friction contact interaction be-
tween bodies exist (Balihodzic, 2002). When there is no contact between the chip and tool, the nor-
mal and shear stresses are tend to zero. A constant friction coefficient, 𝜇, is assumed in the sliding
region. In the analytical model, the coefficient of friction was also considered constant based on the
assumption that the chip slides with a constant friction coefficient on the tool. This friction coeffi-
cient is assumed as 0.15 and related to the friction angle such that (Altintas, 2012):

Fu
𝜇 = tan 𝛽 = (20)
Fv

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Stresses are maximum at the tool edge which is due to sticking friction. Sticking region was modeled
by using Coulomb friction law which is defined by:
{
𝜏f = 𝜇 𝜎n when 𝜇 𝜎n < 𝜏max
(21)
𝜏f = 𝜏max when 𝜇 𝜎n > 𝜏max
where, 𝜏f is the frictional stress, 𝜎n is the normal stress along the tool-chip interface, 𝜏max is the maxi-
mum value of the frictional stress which is assumed to be equal to yield shear stress of the material
(𝜏 ). The friction coefficient used in ABAQUS simulations was 0.15.

3.1. Dynamic analysis of slotting process

Regenerative chatter is one of the most common but undesirable phenomena in cutting processes.
In real applications where the assumption of having a rigid tool does not hold, the cutting forces
from chip cause tool deflection resulting in vibration. The vibration results in wavy surfaces on the
workpiece. The material left by a tooth on the surface of the workpiece, has to be removed by the
one immediately following it. Therefore, the instantaneous chip thickness varies due to vibration and
the time between one tooth to the next (Schmitz & Smith, 2009). The differences in instantaneous
chip thickness cause chatter vibration, poor quality of surface, tool wear and instable cutting.

Cutting force direction in milling process is time dependent which makes the analytical solution
difficult. Smith and Tlusty (1991) overcomes this difficulty by assuming average force direction dur-
ing milling process. Therefore, this assumption causes the system to be time invariant. Tlusty then
projected the assumed average force to the x and y directions using directional orientation factors.
Then the projected results can project onto the surface normal. By obtaining the stability lobe dia-
gram, it is possible to predict the proper values of spindle speed (RPM) and axial depth of cut to
machine efficiently while producing higher quality of products.

The force studied in this section for stability lobe is the maximum force applied to the circular saw
blade. In this case the stability is investigated at the most vulnerable time of the slotting operation
and make the system time invariant and simple. The number of teeth that are in touch with the
workpiece is also the highest in this case. Instead of the average cutting force coefficient given in
(Schmitz & Smith, 2009), the cutting force coefficients when highest force due to the maximum
number of teeth in the process is used.

Defining the oriented Frequency Response Function (FRF) is the first step. Orientation factor can be
obtained by knowing the angle between force and corresponding x or y directions, and then after
projecting in the desire direction, it should be projected onto the surface normal. Thereafter, the fol-
lowing equation can be solved (Smith & Tlusty, 1991):
( [ ])
RE FRForient
[ ]
−1
𝜀 = 2𝜋 − 2tan (22)
IM FRForient

The above equation determines the difference between tooth vibrations over the frequency range.
Finding depth of cut limit (blim) for the frequency range from:

−1
blim = [ ] (23)
2Ks RE FRForient Ne

where, Ks is the applied force coefficient. In the above equation, FRForient = μxFRFx + μyFRFy where, μx
and μy are directional orientation factors. If the direction of the surface normal (n) be towards the
( ) ( )
center of the circular blade, Fn = Fy cos 0 = Fcos(𝛽 − 𝛼) cos 0 = Fcos(𝛽 − 𝛼), so the direction-
al orientation factor μy becomes 𝜇y = cos(𝛽 − 𝛼). To find the other directional orientation factor, Fx
( ) ( )
needs to be projected onto the surface normal, so Fn = Fx cos 90 = Fsin(𝛽 − 𝛼) cos 90 = 0,
and μx becomes zero. Solving the spindle speeds in a frequency range:

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fc 𝜀 (24)
=K+
ΩN 2𝜋

where, fc expressed in Hz, Ω expressed in revolution/second, and K is the integer value (K = 0, 1, 2, …).
f
In (23), ΩN represents tooth passing frequency, and c represents the ratio of the chatter frequency
ΩN
to the forcing frequency. blim vs Ω should be plotted for several K.

4. Results and discussion

To validate the first part of the mathematical model (machine motion configuration) to measure
depth of cut, key times obtained from MATLAB are compared with measurements from experiments
ran by operating the machine with different spindle speed and feed rate as shown in Figure 7.

The parameters selected for this study are given in the Table 1. By solving the mathematical mod-
el for determining uncut chip thickness for each tooth at time steps, 1,216 unique data points are
obtained. It should be noted that the simulation increment is 0.1 s for a blade with 56 teeth. Twenty
data points have been selected for simulation and the remaining data points were estimated using
linear interpolation to predict results.

Obtaining the uncut chip thickness for each teeth at each time step from MATLAB and the avail-
able input data for machine parameters, tooth geometry, and Johnson-Cook model; the finite ele-
ment simulations are conducted in ABAQUS to find out the values for shear angle and shear stress.
The resultant shear angle and shear stress are then used in MATLAB code along with other input
parameters to plot the cutting forces and stability lobe diagram.

Modeling the cutting forces is also considered for a blade which has completed cutting several
slots. In this case, the blade teeth are not sharp, but have not yet been replaced or re-sharpened.
Therefore, the cutting process outputs are compared for two different cases. The first case is for a
sharpened blade considered in its first initial cut. Another case is when the blade teeth are not the
same shape as their original ones, but still are mounted on the slotting machine to finish cutting
slots. The round edge tool for the sharp and dull blade cases are selected as 0 and 0.5 mm,
respectively.

In general, as the uncut chip thickness increases, the difference between uncut and deformed
chip thickness reduces resulting in an increase in chip compression ratio. Shear angle is also related
to chip compression ratio. Therefore, it can be said that by increasing uncut chip thickness, the shear
angle is increased.

Figure 7. Comparison of
calculated and measured time.

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Table 1. Input parameters for the whole cutting process

Blade diameter (mm) 77.98 Pipe thickness (mm) 9.19 Cutting speed (mm/sec) 1,092.2
Blade rake and relief 2, 30 Pipe diameter (mm) 177.8 RPM 255
angle (degree)
Blade teeth number 56 O.D. Slot length (in) 46.78 I.D. Feed rate (mm/min) 50.8
Teeth edge radius 0.01 Friction coefficient 0.5 Final Feed rate (mm/min) 101.6
Blade thickness (in) 0.584 Pipe thickness (mm) 9.19 O.D. Feed rate (mm/min) 76.2

The difference in shear angle for both cases is between 5.4 and 6.7 degrees. Therefore, an angle of
6o is subtracted for all shear angle data points in the sharp case to save the cost of simulations. The
shear stress for dull is 733 × 109 N/m2 which was greater than the previous case (633 × 109 N/m2).

The resultant cutting forces in x and y directions are shown in Figure 8(a) and (b), respectively. The
forces are greater in both directions when the maximum number of teeth is in the workpiece just
before time t2 and before cutting through the workpiece. As the blade passes the time t2 and is fed
downward, the force reduces while the number of teeth that are in touch with the workpiece de-
creases. It is also shown that a dull blade requires greater force in both directions to cut a slot which
shorten the tool life, increase the machining cost, and need to be replaced or re-sharpened.

Although shear power (Ps = Fs .Vs) at the shear plane for the dull blade is greater than that for a
sharp blade, the friction power for both cases is similar referring to Equation (20). This is because the
friction coefficient for both cases is the same (0.15), but it is expected that cutting process using a
dull tooth will have a greater friction coefficient.

Figure 8(c) shows the stability lobe diagram based on the force calculated for the sharp blade. The
blade stiffness is 2.4e7 N/m and dimensionless damping ratio is selected as 0.04. The maximum

Figure 8. Cutting force results.

(a) (b)

(c) (d)

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cutting force coefficient for the time that 12 teeth are engaged is 3.1e10 N/m2. It is possible to de-
termine the stable and unstable regions. These regions are the combination of spindle speed, rpm,
and depth of cut. Therefore, it is possible to choose the spindle speed and depth of cut in a stable
region to avoid tool chatter. It should be noted that by knowing the maximum value of depth of cut,
the value of feed rate can be predicted.

Based on the selection of the rpm value, feed rate, and maximum depth of cut that are selected
for the sharp blade in this section, it can be find that the process is stable (255 rpm and maximum
0.01 mm depth of cut) and there is no chatter in a case of having sharp blade.

Figure 8(d) shows the frequency is calculated for the sharp blade using Fast Fourier Transform
(FFT). The peaks that are shown in Figure 8(d), are tooth passing frequency due to the spindle speed
of 255 rpm. Since the process is stable, no chatter can be seen in the picture.

4.1. Blade geometry optimization

The circular blade is selected to conduct static analysis having the blade fixed at its inner surface due
to the machine configuration and applying the resulting force obtained from numerical simulations
using CATIA FEA. The aim of this section is to investigate the possibility of changing the blade geom-
etry to reduce the blade teeth displacement due to the applied force. Parametric design is used in
CATIA sketch and 3D part for the tool modeling. To design all teeth for the blade, pattern feature
uses one tooth to create all teeth along the outer diameter of the blade. Therefore, the teeth number
automatically are updated when other dimensions are changed. A local sensor should be placed at
the highest applied force to measure the tooth deformation.

There are several constraints that should be included in the problem. The blade has to have
enough material to keep its stiffness; it can reach the plunge and cut the workpiece. The upper limit
for the outer diameter must be specified such that blades are separated by enough distance. The
bore diameter has to be unchanged to mount on the machine arbor. The gullet area has to have
enough space to maintain the chips during cutting. The optimization process can thus be repre-
sented by Equation (22).

( )
objective: min blade deformation

⎧
⎪ outer diameter − bore diameter > 1.5in
⎪ 2in < outer diameter < 4in
⎪
⎪ bore diameter = 1in
⎪ 2deg < rake angle < 40deg
cstr: ⎨ (22)
⎪ 3deg < relief angle < 30deg
⎪ 0.06in < tooth height < 0.15in
⎪ 0.14in < tooth pitch < 0.2in
⎪
⎪ 0.01in < gullet radius < 0.05in
⎩

Updated design geometries after optimization process for the blade shows decrease in the outer
diameter (72.39 mm), number of teeth (50), relief angle (25°), and teeth height (1.62 mm). However,
it is observed that increase in rake angle (5°) reduces the blade deformation which improves the tool
life. Decrease in the relief angle as rake angle rises is important to maintain blade stability during
cutting. The gullet radius (0.66 mm) and teeth pitch (4.54 mm) need to be increased for a better tool
life.

Since the blade geometry has changed, the applied force at the time that maximum number of
teeth are in contact with the workpiece is to be find. Therefore, the optimized blade geometry should
be input in the MATLAB code and FEA simulation to obtain the cutting force that can be used in the

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Figure 9. Deflection of the

blades in static analysis.

static analysis to measure the blade displacement. Figure 9 shows the highest blade’s teeth defor-
mation of 0.019 mm and 0.017 mm for before and after modification, respectively.

5. Conclusion
In the methodology employed for this research, analysis of forces involved in the cutting process
was the major component. An algorithm designed to solve an analytical model specifically devel-
oped for a multi-spindle slotting machine that uses thin circular saw blades was used for the force
analysis. The model development has accounted for the different time steps caused by the differ-
ence in feed rates at progressive stages in the process of the slotting through the pipe. Results from
these analyses were later applied to study the chatter frequency during the machining process, and
conduct optimization on the geometry of the blade.

Cases where slotting machine included sharp and/or dull blades were investigated by combining
analytical models and simulations for the respective scenarios. As expected, dull blades caused
significantly higher force requirements and blade displacement. As this condition leads to significant
increase in the cost incurred by the operation, monitoring of the blades to keep sharp blades on the
machine at all times needs to be implemented. The accuracy of the system that is to be used to
monitor shall be given enough emphasis to make sure that dull blades do not reduce the efficiency
of the process and/or quality of the product.

The shear angle values that resulted from FE simulations came in good agreement with results
from analytical calculation. Therefore, the satisfactory application of the developed analytical model
to predict the slotting process’ parameters was strongly indicated. Furthermore, this research dem-
onstrated that the methodologies presented can be applied for any future case to form a basis in the
tool selection for a given pipe material.

Optimization was conducted to identify the new blade geometry for improved performance. By
making use of the results from the force analysis the optimal blade geometry and dimensions were
determined. It was concluded that, if changing the blade geometry for better tool life is considered,
the specifications given in Table 1 shall be followed.

Acknowledgement Author details

Special thanks is hereby extended to Mr Michael Leitch Yazdan Kordestany1
(PEng) for his invaluable contributions during the entire E-mail: [email protected]
course of the research. Yongsheng Ma1
E-mail: [email protected]
Funding
ORCID ID: http://orcid.org/0000-0002-6155-0167
This work was supported by the RGL Reservoir 1
Mechanical Engineering Department, University of Alberta,
Management Inc; Natural Sciences and Engineering
#10-235 Donadeo ICE Building, Edmonton, Alberta, T5G 1H9,
Research Council of Canada [grant number RGPIN 5641].
Canada.

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Citation information abaqus. Advanced Materials Research, 821–822, 1410–

Cite this article as: Force calculation using analytical and 1413. Retrieved from http://www.scientific.net/
CAE methods for thin-blade slotting process, Yazdan AMR.821-822.1410
Kordestany & Yongsheng Ma, Cogent Engineering (2017), Matanovic, D., Cikes, M., & Moslavac, B. (2012). Sand control in
4: 1412106. well construction and operation. Springer.
https://doi.org/10.1007/978-3-642-25614-1
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