Cutter head forces and load cell scanning

Among the machinery found in wood manufacturing industries, routers and planers are the most commonly used. These tools, which many times are mounted on metal cylinders, actually operate only briefly, i. e., when a chip is cut from a piece of wood under process. The rest of the time the knife follows the cylinder surface and a cycloid is formed relative to the work piece, which in turn is fed into the machine. A number of knives are mounted on the cutter, which ascertain that the planed surface will become sufficiently planed and does not show too a wavy pattern. This works fine for high revolutions and low feeding speeds even if problems sometimes occur. Factories, however, naturally want to increase the overall manufacturing speed, which means that at the same time more defects are introduced at the planed surface. These defects are the result of the cutting process. In this paper, we examine, by use of a load cell, how the cutting forces vary during the formation of a wood chip. Wood is not an isotropic material and knots and other anomalies make the evaluation harder. In order to simplify the conditions, experiments are also shown from the cutting of a plastic polymer material as well as Medium Density Fibreboard (MDF). It is shown that the work piece vibrated intensely which littered all output data from the cell. Experience from the experiments however made it possible to design a computerised filter which saved only those registrations which were of interest while the others were set to zero. For beech, the forces were found to be of the magnitude 50 N/cm opposite to the feeding direction while the tranverse forces changed signs and had a magnitude of about 5 N/cm.     

Application of fracture mechanics for energetic effects predictions while wood sawing

In the classical approach, energetic effects (cutting forces and cutting power) of wood sawing process are generally calculated on the basis of the specific cutting resistance, which is in the case of wood cutting the function of more or less important factors. On the other hand, cutting forces (or power—more interesting from energetic point of view) could be considered from a point of view of modern fracture mechanics. Cutting forces may be employed to determine not only toughness but also shear yield strength, which are then applied in the models. Furthermore, forecasting of the shear plane angle for the cutting models, which include fracture toughness in addition to plasticity and friction, broadens possibilities of energetic effects modelling of the sawing process even for small values of the uncut chip. Mentioned models are useful for estimation of energetic effects of sawing of every kinematics. However, for band saws and circular sawing machines, the chip acceleration power variation as a function of mass flow and tool velocity ought to be included in analysis of sawing at larger cutting speeds.     

木材切削阻力测定中刀具锋利程度的控制

本文从木材试样内切削阻力的变异和不同条件下代表一定刀具锋利程度差异的切削祖力差异的变异两个方面,论证了在直角自由切削主切削测定中,通过对木材试样的试切削进行刀具锋利度控制的有效性,并为此种方法的合理运用提供了依据。     

不同树种木材切削阻力变动模型

根据１１种针叶树材和１５种阔叶树材切削阻力的研究结果，推出不同树种木材主切削力变动模型，描述不同树种木材切削阻力在不同切削条件下变动的规律，并可对此种变动进行估计。模型由三部分组成：不同条件下切削阻力的平均水平；不同树种中切削厚度、刀具前角和木材含水率对切削阻力的影响；不同条件下木材密度与切削阻力的关系。     

数控微米刨切试验台的设计与试验

为解决传统热磨法加工微米薄木片及木纤维中高能耗、工序复杂、加工成本高的缺点,现改变加工方法,采用顺纹纵向刨切木材的方式,研发了数控微米刨切试验台。试验台主要由机架、纵向进给机构总成、工件夹具、控制面板、刨切机构总成、升降机构总成和限位机构组成,可对宽度为50 mm,长度为300～600 mm,高度为20～90 mm的木材工件进行纵向进给、切削量进给和刨切作业。笔者对试验台整机以及各机构进行设计,并通过ANSYSY对刀具进行强度校核。通过试验,确定刨切机构切削角δ取45°,刀刃伸出量h取0.05 mm,刀门宽度d取0.2 mm,刨得的木片平均厚度为18.7μm,最薄为15μm。最后通过显微镜观察发现经过刨切后的刀刃部分出现磨损,可通过表面改性提高刀具的耐磨性。     

带锯机锯轮转速、锯条摆动与锯解精度的试验研究

基于对木工带锯机加工特性的研究需要,本文在MJ397型高速木工带锯机的锯条张紧力和进给速度恒定的情况下,通过实测锯机工作台和锯条结构系统的固有频率、同条件下锯割杉木试材时的锯条横向摆动量、变频器调节锯轮转速和锯材表面粗糙度等,分析锯轮转速、锯条横向摆动量与锯解精度的关系,为优化国产带锯机锯割稳定性等设计工作提供依据.     

木质材料无屑切削机理及切削力的研究

对木质材料切削中比较特殊的一类切削方式———无屑切削的切削机理及切削力进行了理论上的研究,并在单板切条试验机上进行试验验证。研究证明,楔型刀锯进行木质材料无屑切削时,其切削力受木材的树种、切削方向、锯片尺寸、角度参数及切削用量的影响较大。     

不同织构形式硬质合金表面与木材径切面的摩擦性能

合理的微坑型微织构已被证明具有改善木材和硬质合金表面间的摩擦特性。采用微凹坑型织构、微凹槽织构和微网格型织构3种织构形式,在相同织构面积占有率条件下,通过摩擦特性试验与理论分析相结合,研究不同织构形式对木材表面摩擦系数的影响。研究表明:在相同织构面积占有率条件下,不同织构的类型和表面形貌对硬质合金试样与木材表面摩擦的摩擦系数有不同的影响,受摩擦长度、凹槽微织构宽度、微织构角度等织构参数的影响。当微织构与木材发生摩擦时,摩擦区域织构面积越大说明两者间实际接触面积越小,且面积越大,捕捉磨屑和硬质点的能力越强;而主制动力越小,其产生的摩擦系数越小。在相同压力和织构面积占有率条件下,不同类型的织构试件与木材表面产生的摩擦系数均小于非织构(平面)型表面产生的摩擦系数。其中:微坑型织构产生的表面摩擦系数最小,为0.116;凹槽型织构产生的表面摩擦系数最大,为0.182;网格型织构随着织构角度的减小,其产生摩擦系数越小。     

自制测力仪用于木材三向切削力的测定

评定木材切削刀具的切削性能及切削表面的加工质量时，均需测定木材切削时的三向切削力：主切削力、进给力及侧向力，因此设计一台合适的三向测力仪成为关键。本文以单一八角环为基础，引申出单向延伸式八角环、组合式八角环及双向延伸式八角环测力仪，并逐一分析其结构特点及应用于木材三向切削力测定的可行性。最终确定双向延伸式四耳环八角环性能最优，并对其进行设计、制选、标定及切削试验。试验结果表明该型完全符合木材三向切削力测定的要求。     

Orthogonal cutting mechanics of maple: modeling a solid wood-cutting process

The experimental results of orthogonal cutting of maple and the modeling of the cutting mechanics are presented. The tool cutting forces were measured for different feed rates. A set of equations relating the tangential and feed forces to the tool edge width and feed rate (chip thickness) to calculate the chip and edge cutting force coefficients was developed. Then the chip force and edge force coefficients were calculated from experimentally obtained cutting forces and were plotted in a polar-coordinate system with respect to the fiber orientation of the maple disk. The polar-coordinate presentation of the cutting force results and the calculated cutting force coefficients provides an excellent visual appreciation of the relation between the cutting forces and the wood fiber orientation. Chips were also collected from various sectors of the wood disk. This analysis further identified the effects of fiber orientation and cutting forces on the types of chip formed and hence the cutting mechanics involved. By applying the calculated cutting coefficients for each tool orientation (in respect to the grain) it is possible to predict the feed and tangential forces for any feed rates. There is good agreement between the predicted and measured cutting forces.     

红松水曲柳木材密度与切削阻力关系的研究

本文继前一报告之后,对红松、水曲柳木材密度与切削阻力的关系做了进一步的研究。主要的结果是:(1)木材密度与切削阻力的关系因树种、切削方向、切削厚度、刀具前角和木材含水率之不同而有差异;(2)切削厚度、刀具前角和木材含水率对密度与切削阻力关系的影响有统一的趋势,而且此趋势可用简单的线性关系表述;(3)木材中密度以外的影响切削阻力因素的分布状况,从株内较大范围看,半径和树高方向不同部位间均未表现出显著差异。     

Towards a model predicting cutting forces and surface quality in routing layered boards

The general aim of work reported here was to assist designers and operators of routers and similar tools for cutting wood-composite boards, by providing a model predicting cutting force components from readily available material properties. This initial study explored, for edge cutting, the variation within a single medium density fibre board across the thickness and in various cutting directions in the plane of the board. Material properties of interest were specific gravity and friction coefficient. In slow linear cutting on a modified milling machine, carbide router inserts cut the edges of layers cut from a medium density fibre board. Specific gravity and coefficient of sliding friction were measured for each layer. Cuts were also made on full-thickness edges in various directions in the plane of the board. Chip thickness was varied from 0.025 to 0.8 mm. Parallel and normal force data and digital video images of chip formation were stored for analysis. Specific gravity increased as the fourth power of the distance from the central plane to the surface. Friction coefficient values, estimated both from cutting forces and from rubbing forces during return, varied about a value of 0.23, with no significant difference between layers. The values for cutting force per mm width of cut increased progressively from the central plane to the surface, in a logarithmic relation with specific gravity. The cutting forces did not vary with cutting direction in the plane of the board. For a sharp edge with 32° rake angle cutting at chip thickness values above 0.1 mm, the normal force component was negative, indicating reduced feed force and improved surface quality. With dulling, the threshold value of chip thickness for this increased. It is concluded that elaboration of this approach would generate relationships suitable for incorporating in a useful general model. However, it may be found that weight per unit area of board will suffice as a proxy for cutting resistance in modelling the cutting of full-thickness edges. Received 10 June 1999     

STUDY AND ANALYSIS OF CUTTING FORCES ON OBLIQUE CUTTING OF WOOD

Oblique cutting of wood is an important form of cutting wood.With the developingof woodworking industry,it is widely used in wood machinary processing such as planing,milling,sawing,drilling and so on.This paper takes oblique planing and helix milling of wood as examples.The influences of bevel angle and other factors on the cutting force have been shown.The changingrules of cutting forces have been summarized.On the basis of it,we especially carried out theoreticalanalysis on the changing rules of cutting forces and discussed the influence of the changing rules onpractice.     

Three-dimensional finite element modelling of heat transfer for linear friction welding of Scots pine

Finite element numerical analyses were performed to determine three-dimensional heat flux generated by friction to wood pieces during linear friction welding. The objective was to develop a computational model to explain the thermal behaviour of welded wood material rather than experimental methods, which are usually expensive and time consuming. This model serves as a prediction tool for welding parameters, leading to optimal thermo-mechanical performance of welded joints. The energy produced by the friction welding of small wood specimens of Scots pine (Pinus sylvestris L.) was determined by thermocouples and used as input data in the model. The model is based on anisotropic elasticity and the thermal properties were modelled as isotropic. This numerical simulation gave information on the distribution of the temperature in the welding interface during the entire welding process. A good agreement between the simulation and experimental results showed the appropriateness of the model for planning welded wood manufacture and prediction of thermal behaviour of wood during other mechanically induced vibration processes. The specimens presented in this model required a heat flux of 11 kW/m² to achieve a satisfactory welding joint.     

11种针叶树材的切削厚度、刀具前角和木材含水率对切削阻力影响的研究

对11种针叶树材在0-90、90-0和90-90三个切削方向的高速直角自由切削的试验研究表明:1)切削厚度、刀具前角和木材含水率对主切削力影响的基本趋势,各树种基本一致,但定量考察有一定的差异;2)三因素影响的阻力比值R_t、R_a和R_w在不同树种中变异不大;3)三因素对切削阻力的影响存在一定的交互作用,在不同切削方向,情况有所不同。     

圆锯片适张状态检测方法的研究(英文)

文章论述了一种圆锯片适张状态的检测方法及实现的系统 .该方法采用锯片适张前后固有频率的变化幅度 ,锯片单点加载情况下一定半径圆周上的横向变形量和端面圆跳动三个特征参量 ,表述一个锯片的适张程度、适张均匀性和平整性 .应用计算机控制的检测系统 ,经过对大量不同规格木工锯片和大型金刚石锯片的检测 ,结果表明该方法是切实可行的     

The effect of rotation speed on the power consumption and cutting accuracy of guided circular saw: Experimental measurement and analysis of saw critical and flutter speeds

ABSTRACT

This paper investigates the effect of rotation speed and vibration response of a circular saw on the sawing process of Douglas-fir wood. An idling test was conducted on a guided circular saw to determine its stable operation speeds and vibration behavior. Short-time Fourier transform analysis was performed on saw idling test data, and variation of excited frequencies of the blade as a function of rotation speed was obtained. The saw blade critical speeds and the rotation speeds that correspond to saw flutter instability were identified. Then experimental cutting tests were conducted at different cutting conditions and the effect of rotation speed and saw vibration response on cutting power consumption and sawing accuracy was investigated. The results showed that conducting a saw idling test and vibration response analysis can identify the saw critical and flutter speeds, which is essential for identifying the optimum rotation speed of circular saw. There was a significant increase in power consumption when cutting at super-critical and super-flutter speed. The effect of rotation speed on sawing accuracy is complex and nonlinear. This effect interacts with feed speed, which makes it difficult to generalize sawing accuracy versus rotation speed in the circular sawing process.     

A review on wood machining: characterization,optimization, and monitoring of the sawing process

ABSTRACT

Sawing is the most common machining process and is present in both primary and secondary wood transformation sectors. The objective of this paper is to review how it is affected by different factors. The current challenges associated with various machining factors, process monitoring, and sensor selection were identified and explained. Consequently, four research challenges and technological gaps were outlined. (1) Contradictory results have been reported due to different cutting processes, wood species, measurement methods, and cutting speed range studied in literature, so special consideration needs to be taken when comparing results with those available in the literature. (2) Laboratory test conditions cannot yet fully represent the extreme cutting conditions in sawmills. More emphasis should be placed on those harsh industrial cutting conditions. (3) Research on wood cutting lacks multi-objective optimization approach, which suggests that sawdust generation should be simultaneously analysed with surface quality and power consumption. (4) Compared with metal cutting, little research has been conducted on wood sawing monitoring using an artificial intelligence approach, which should be prioritized in designing adaptive control systems. Combining intelligent monitoring and multi-objective optimization approaches should pave the way for controlling the sawing process so higher surface quality and cost efficient machining is achieved.     

Evaluation of wood cutting forces in dry and wet conditions by small-scale chipping tests applying different analysis methods

ABSTRACT

The aim of this paper is to study the effect of high moisture content in comparison to dry timber on the resulting cutting forces based on experimental small-scale chipping tests. Therefore, a wood chipper for single cuts is designed and different species of Austrian locally growing trees are utilized. The test specimens are investigated in almost dry and soaked wet conditions. The resistance of wood is measured utilizing a force sensor and the signal during the cutting process is subsequently analysed by two different methods. The results reveal that the mean value of the acting force during cutting is 38–81% minor compared to the maximum force. Even though the peak of the dynamically acting load is measured for just a comparably small time range, it reveals an impact on the fatigue behaviour of the tool as well as the tool supporting material. Hence, an approach of evaluated load spectra is applied to include the load distribution of the chipping process. The effect of dry and wet wood on the cutting resistance is examined, whereby wood exhibiting a high moisture content of 30–40% changes the acting load up to 98%, depending on the method of analysis.