Effect of Feed Rate on the Force and Energy in the Cutting Process Using Planar Technical Blades

Round 1

Reviewer 1 Report

This study analyzed the effect of cutting blade feed rate on cutting force and energy consumption of the fish skinning process. This work is interesting and has been well presented. The following minor questions should be revised before future publication.

1. Abstract: the expression of “as the feed rate increasing feed rate…” should be improved.

2. Introduction: the writing of the research purpose and current situation is fine. The value of the angle has a substantial effect on the energy intensity of the cutting process, especially for engineering materials. Hence, besides reference [11], Some lately publications on the angle of cutting edge on cutting performance should be added to enrich your literature review. See https://doi.org/10.1016/j.jmrt.2022.12.054. https://doi.org/10.1016/j.cja.2022.12.009.

3. Introduction: the definition of α and α1 should be given in “The values of wedge angle that are frequently used in the food sector are in the range of α = 3–10° and α1 = 20–30°”.

4. There are at least four names for cutting speed, cutting blade feed rate, feed rate, cutting feed rate. It should be unified.

5. The cutting force measurement unit should be clearly pointed out in Fig. 1.

6. The fluctuation of curves in Fig. 7 and 8 is obvious, especially at vf=280 to 340. What is the cause?

7. The quality of the language is ok. In general, the language could be refined carefully with the help of a native English speaker.

Author Response

The Authors wish to thank all the Reviewers for their time spent on prepare review of the manuscript “Effect of Feed Rate on the Force and Energy in Cutting Process Using Planar Technical Blades”. All the valuable comments, suggestions and hints were very helpful in improving the readability of the text and in improving of its scientific quality. Below the detailed responses upon these subsequent comments were given. The modified or added text in the manuscript was highlighted in red.

 

REVIEWER 1

This study analyzed the effect of cutting blade feed rate on cutting force and energy consumption of the fish skinning process. This work is interesting and has been well presented. The following minor questions should be revised before future publication.

Reviewer comment 1:

Abstract: the expression of “as the feed rate increasing feed rate…” should be improved.

Authors response:

According to the reviewer's comment, the sentence in line 19 has been corrected:

“The results indicated the most favorable feed rate parameter and showed a clear relationship between the feed rate and the forces and energy expenditure: as the feed rate increased, an upward trend in forces and energy expenditure was noted.”

Reviewer comment 2:

Introduction: the writing of the research purpose and current situation is fine. The value of the angle has a substantial effect on the energy intensity of the cutting process, especially for engineering materials. Hence, besides reference [11], Some lately publications on the angle of cutting edge on cutting performance should be added to enrich your literature review. See https://doi.org/10.1016/j.jmrt.2022.12.054. https://doi.org/10.1016/j.cja.2022.12.009.

Authors response:

The authors reviewed the proposed works and included them in the sources. The relevant information was included in the line 78:

“Liu et al. [18] and Sun et al. [19] in their works, in addition to blade angle and cutting speed, point out other important factors related to the cutting characteristics of plastics such as the introduction of vibrations, which can have a significant impact on the forces involved in the process and the surfaces left after cutting.”

Reviewer comment 3:

Introduction: the definition of α and α1 should be given in “The values of wedge angle that are frequently used in the food sector are in the range of α = 3–10° and α1 = 20–30°”.

Authors response:

According to the reviewer's comment, the sentence in line 66 has been corrected:

“The values of wedge angle that are frequently used in the food sector are in the range of α = 3–10° and α1 = 20–30°, where α stands for cutting blade tip angle, and α1 stands for cutting blade wedge angle.”

Reviewer comment 4:

There are at least four names for cutting speed, cutting blade feed rate, feed rate, cutting feed rate. It should be unified.

Authors response:

According to the reviewer's comment, the terminology has been unified as cutting blade feed rate. Changes were marked in document text.

Reviewer comment 5:

The cutting force measurement unit should be clearly pointed out in Fig. 1.

Authors response:

According to the reviewer's comment, the cutting force measurement unit has been pointed, and Figure 1 was updated.

Figure 1. General view of the measuring station.

Reviewer comment 6:

The fluctuation of curves in Fig. 7 and 8 is obvious, especially at vf=280 to 340. What is the cause?

Authors response:

Authors decided to extend the analysis of the results with a description of the basic phenomena occurring in the process of cutting soft tissues. Conducting this analysis also made it possible to attempt to explain to the reader other observed phenomena (such as the decrease in forces at the blade feed rate of 340 mm/s). Reference was added in line 436 of the manuscript. Authors made necessary changes to the manuscript in line 275:

“On the basis of the collected data, it is possible to observe characteristic points, such as a sudden decrease in force F at 380 mm/s, a decrease in the energy intensity of the cutting process ej at 340 mm/s, and a decrease in work W and power P at a blade feed rate of 340 mm/s. To explain these phenomena, which are a deviation from the general trend according to which the recorded data follow, it is necessary to discuss the basic phenomena occurring in soft tissue decohesion. Zhongwei Hu et al. [28] detail the following phases in the process of soft tissue cutting:

• deformation phase,
• rupture phase (preceded by a break-in point),
• cutting phase.

The deformation phase occurs before the break-in point, which initiates the rupture and subsequent cutting process. In this phase, the blade penetrates the sample but does not separate, causing the sample to become strained. Increasing the sample deformation stress leads to entering the rupture phase, which is more violent as the sample deformation stress increases. Once the blade reaches the „break-in point”, a fracture begins and rapidly spreads, leading to the tissue rupture phase. In the rupture phase, the blade hardly exchanges energy with the tissue. The energy absorbed by the sample is immediately released. The area of newly formed cracks depends on the energy absorbed in the deformation phase. The more energy was absorbed in the previous phase, the larger the crack surface was formed in the rupture phase. The cutting phase immediately follows, in which the cutting force varies less than in the previous phases [28].

Due to the different kinematics of movement to that reported so far in the literature, and due to the thickness of the specimens, it is difficult to detail the cutting phase in the presented graphs (Fig. 6). Conclusions are drawn based on the cutting force F, when the „break-in point” is reached. However, analysis of the basic phenomena occurring in the process of cutting through soft tissues allows the authors to put forward a hypothesis. The phenomena of reduction of energy expenditure and cutting forces F located in the vicinity of the feed rate of 340-380 mm/s are related to the stresses introduced into the material. At these particular feed rates, the deformation phase is shortened, but intensified, leading to a rapid transition to the rupture phase while reaching the "break-in point" earlier.”

Reviewer comment 7:

The quality of the language is ok. In general, the language could be refined carefully with the help of a native English speaker.

Authors response:

Authors of the manuscript thank for feedback. We hope that in preparing the article for print, the editors will refine language.

Author Response File: Author Response.doc

Reviewer 2 Report

The paper presents practical research  on the Force and Energy in the fish cutting process.  The work  is more like an experimental report which has industrial relevance. However, the theory is lacking. The following factors need to be addressed for publication:

 

1. In Figure 5, it is suggested to take the image after the fish is mounted in the jaws.

2. In Figure 6(a), the color of the lines is almost the same. Please use other expressions.

3. It is recommended to use different angles of the blade for testing. Different geometric parameter models are established, and the optimization of cutting tools and processing parameters is completed according to the cutting parameters.

4.The effect of cutting should be the result that must be considered, the manuscript lacks relevant explanation.

Author Response

The Authors wish to thank all the Reviewers for their time spent on prepare review of the manuscript “Effect of Feed Rate on the Force and Energy in Cutting Process Using Planar Technical Blades”. All the valuable comments, suggestions and hints were very helpful in improving the readability of the text and in improving of its scientific quality. Below the detailed responses upon these subsequent comments were given. The modified or added text in the manuscript was highlighted in red.

REVIEWER 2

The paper presents practical research on the Force and Energy in the fish cutting process.  The work is more like an experimental report which has industrial relevance. However, the theory is lacking. The following factors need to be addressed for publication:

Reviewer comment 1:

In Figure 5, it is suggested to take the image after the fish is mounted in the jaws.

Authors response:

The laboratory bench has not been adapted for mounting a fish, it is only to reproduce the kinematics of the process when cutting through specially prepared specimens imitating soft tissues (in this case – polyurethane). In the article information about this was provided in line 167 as follows:

“The study conducted by other writers on the comparable cutting methods [11-12, 26] detailed in Section 1 of this article served as the foundation for the selection of this material, because it has been shown that polyurethane can replace soft tissue in laboratory tests.”

Cutting through a fish in the laboratory is not feasible for logistical and economic reasons and this is related to lab conditions. The authors claim that after laboratory tests, it is necessary to conduct further research and verify the results in industrial conditions, on a production line. Relevant information has been given in the conclusions, in the line 365 of the manuscript:

“Since the studies presented are of a laboratory nature, it is not possible to replicate under such circumstances the effect of variables that occur in a manufacturing process. As a result, tests performed on the test bench mentioned above must finally be confirmed by experiments carried out in a production line conditions for flat fish skinning process.”

Reviewer comment 2:

In Figure 6(a), the color of the lines is almost the same. Please use other expressions.

Authors response:

In accordance with the reviewer's comment, the authors corrected Figure 6 to improve its readability. The authors decided to abandon the lower label in favor of flags describing blade feed rates used when recording individual data.

Figure 6. Collection of experimental results of cutting force F relative to cutting feed rate: (a) averaged cutting force curves for each cutting feed rate; (b) measured values of cutting force, mean values, and the impulse I of force F.

Reviewer comment 3:

It is recommended to use different angles of the blade for testing. Different geometric parameter models are established, and the optimization of cutting tools and processing parameters is completed according to the cutting parameters.

Authors response:

Studies devoted to other blade geometries and their effect on process have been described in previous research (https://doi.org/10.3390/mi12121516). In addition, authors refer to other sources describing effect of blade angles in line 72 of the manuscript:

“The value of the angle has a substantial effect on the energy intensity of the cutting process, depending on the application and the material being machined [11]. The authors of an investigation [12] study the impact of both edge rounding radius and blade angle. The cutting force measurements made throughout the cutting process have a high correlation with blade sharpness. The geometry of the blade, particularly its wedge angle and tip radius, is one of the most significant elements affecting cutting force. Information about how these factors affect cutting forces may be found in the literature [12–17].”

Optimization of process parameters and control of the angle of application of the cutting blade is planned in further work dedicated to this issue.

Reviewer comment 4:

The effect of cutting should be the result that must be considered, the manuscript lacks relevant explanation.

Authors response:

The effect of cutting through the samples resulted in recorded forces, which are analyzed in the article. In accordance with the comment of the reviewer, the authors decided to extend the analysis of the results with a description of the basic phenomena occurring in the process of cutting soft tissues. Conducting this analysis also made it possible to attempt to explain to the reader other observed phenomena (such as the decrease in forces at the blade feed rate of 340 mm/s). Reference was added in line 419 of the manuscript. Authors made necessary changes to the manuscript in line 275:

“On the basis of the collected data, it is possible to observe characteristic points, such as a sudden decrease in force F at 380 mm/s, a decrease in the energy intensity of the cutting process e_j at 340 mm/s, and a decrease in work W and power P at a blade feed rate of 340 mm/s. To explain these phenomena, which are a deviation from the general trend according to which the recorded data follow, it is necessary to discuss the basic phenomena occurring in soft tissue decohesion. Zhongwei Hu et al. [28] detail the following phases in the process of soft tissue cutting:

• deformation phase,
• rupture phase (preceded by a break-in point),
• cutting phase.

The deformation phase occurs before the break-in point, which initiates the rupture and subsequent cutting process. In this phase, the blade penetrates the sample but does not separate, causing the sample to become strained. Increasing the sample deformation stress leads to entering the rupture phase, which is more violent as the sample deformation stress increases. Once the blade reaches the „break-in point”, a fracture begins and rapidly spreads, leading to the tissue rupture phase. In the rupture phase, the blade hardly exchanges energy with the tissue. The energy absorbed by the sample is immediately released. The area of newly formed cracks depends on the energy absorbed in the deformation phase. The more energy was absorbed in the previous phase, the larger the crack surface was formed in the rupture phase. The cutting phase immediately follows, in which the cutting force varies less than in the previous phases [28].

Due to the different kinematics of movement to that reported so far in the literature, and due to the thickness of the specimens, it is difficult to detail the cutting phase in the presented graphs (Fig. 6). Conclusions are drawn based on the cutting force F, when the „break-in point” is reached. However, analysis of the basic phenomena occurring in the process of cutting through soft tissues allows the authors to put forward a hypothesis. The phenomena of reduction of energy expenditure and cutting forces F located in the vicinity of the feed rate of 340-380 mm/s are related to the stresses introduced into the material. At these particular feed rates, the deformation phase is shortened, but intensified, leading to a rapid transition to the rupture phase while reaching the "break-in point" earlier.”

Author Response File: Author Response.doc

Reviewer 3 Report

In the presented work, an attempt was made to study the effect of feed rate on the force and energy while cutting polyurethane using planar technical blade. The manuscript is well organized and written. The paper is of appropriate length. The title and abstract are satisfactory. The figures and tables are appropriate and informative. I found the approach and conclusions to be robust and useful. The number of bibliographic references is sufficient. The state-of-the-art review presented in the Introduction part is comprehensive and follows a good logical structure. The testing guidelines and equipment used for carrying out the experiments are fully provided, and the obtained results are thoroughly presented and discussed accordingly. Finally, the Conclusions part does a good job in wrapping up the paper by summarizing the main findings. However, here are some comments and suggestions which can help improve the quality of the manuscript.

·       In the abstract, the feed should be 70-100 mm/sec.

·       The authors should inform to the audience what is novel in the work carried out.

·       “The maximum calculated work took the value of 0.015 J for a feed rate of 340 mm/s and the maximum power values were 3.95 W for a feed rate of 310 mm/s.” Why the maximum work and power are obtained at different feed values? But. the minimum work and power obtained for the same feed of 280 mm/s.

·       Why there is a decrease in force above the feed value of 340 mm/sec?

·       Images are not clear. High quality images should be used.

Author Response

The Authors wish to thank all the Reviewers for their time spent on prepare review of the manuscript “Effect of Feed Rate on the Force and Energy in Cutting Process Using Planar Technical Blades”. All the valuable comments, suggestions and hints were very helpful in improving the readability of the text and in improving of its scientific quality. Below the detailed responses upon these subsequent comments were given. The modified or added text in the manuscript was highlighted in red.

REVIEWER 3

In the presented work, an attempt was made to study the effect of feed rate on the force and energy while cutting polyurethane using planar technical blade. The manuscript is well organized and written. The paper is of appropriate length. The title and abstract are satisfactory. The figures and tables are appropriate and informative. I found the approach and conclusions to be robust and useful. The number of bibliographic references is sufficient. The state-of-the-art review presented in the Introduction part is comprehensive and follows a good logical structure. The testing guidelines and equipment used for carrying out the experiments are fully provided, and the obtained results are thoroughly presented and discussed accordingly. Finally, the Conclusions part does a good job in wrapping up the paper by summarizing the main findings. However, here are some comments and suggestions which can help improve the quality of the manuscript.

Reviewer comment 1:

In the abstract, the feed should be 70-100 mm/sec.

Authors response:

The range of velocities subjected to observation and testing in the article is from 70 mm/s to 400 mm/s. According to reviewer’s comment, authors corrected “ms” to “mm/s” in line 17 of the manuscript.

Reviewer comment 2:

The authors should inform to the audience what is novel in the work carried out.

Authors response:

The approach in which the range of measured velocities on the test bench is very wide (in this case from 70 mm/s up to 400 mm/s), with the number of measurement points used, is a novel element. As per reviewer's comment, relevant information was put in Section 1, in line 110:

“A novel element distinguishing this work is the approach in which the range of measured velocities on the test bench is very wide (in this case from 70 mm/s to 400 mm/s). In addition to relying on a wide range of feed rates for testing, a novel element of the study of cutting specimens that mimic soft tissues is the use of the author's rectilinear motion kinematics test stand equipped with a high-speed data acquisition system.”

Reviewer comment 3:

“The maximum calculated work took the value of 0.015 J for a feed rate of 340 mm/s and the maximum power values were 3.95 W for a feed rate of 310 mm/s.” Why the maximum work and power are obtained at different feed values? But. the minimum work and power obtained for the same feed of 280 mm/s.

Authors response:

Directly, such a situation arises from the recorded data and the calculations made, while indirectly, these specific values may have been affected by the heterogeneity of the material (which is also the case with the process being mapped), other variables or characteristics of cutting process and basic phenomena occurring in cutting process. As suggested by the reviewers, the analysis has been expanded. Fundamental phenomena occurring in the process of soft tissue cutting have also been analyzed. The analysis made it possible to put forward a hypothesis on the occurrence of characteristic points observed in the recorded data set. Reference in line 436 was added to the manuscript. Relevant changes have been made in the line 275 of the manuscript.

Reviewer comment 4:

Why there is a decrease in force above the feed value of 340 mm/sec?

Authors response:

It can be concluded that the value of this parameter in terms of the research conducted seems to be the most favorable. Further research in a narrower range close to this measurement speed should be carried out to determine the reason for the occurrence of the lowest cutting force at this particular speed in terms of force-displacement relationship. As mentioned above, the authors, in response to the reviewers' comments, decided to expand the data analysis in Section 3. Reference was added in line 436, and appropriate changes were made to the manuscript in line 275:

“On the basis of the collected data, it is possible to observe characteristic points, such as a sudden decrease in force F at 380 mm/s, a decrease in the energy intensity of the cutting process e_j at 340 mm/s, and a decrease in work W and power P at a blade feed rate of 340 mm/s. To explain these phenomena, which are a deviation from the general trend according to which the recorded data follow, it is necessary to discuss the basic phenomena occurring in soft tissue decohesion. Zhongwei Hu et al. [28] detail the following phases in the process of soft tissue cutting:

• deformation phase,
• rupture phase (preceded by a break-in point),
• cutting phase.

The deformation phase occurs before the break-in point, which initiates the rupture and subsequent cutting process. In this phase, the blade penetrates the sample but does not separate, causing the sample to become strained. Increasing the sample deformation stress leads to entering the rupture phase, which is more violent as the sample deformation stress increases. Once the blade reaches the „break-in point”, a fracture begins and rapidly spreads, leading to the tissue rupture phase. In the rupture phase, the blade hardly exchanges energy with the tissue. The energy absorbed by the sample is immediately released. The area of newly formed cracks depends on the energy absorbed in the deformation phase. The more energy was absorbed in the previous phase, the larger the crack surface was formed in the rupture phase. The cutting phase immediately follows, in which the cutting force varies less than in the previous phases [28].

Due to the different kinematics of movement to that reported so far in the literature, and due to the thickness of the specimens, it is difficult to detail the cutting phase in the presented graphs (Fig. 6). Conclusions are drawn based on the cutting force F, when the „break-in point” is reached. However, analysis of the basic phenomena occurring in the process of cutting through soft tissues allows the authors to put forward a hypothesis. The phenomena of reduction of energy expenditure and cutting forces F located in the vicinity of the feed rate of 340-380 mm/s are related to the stresses introduced into the material. At these particular feed rates, the deformation phase is shortened, but intensified, leading to a rapid transition to the rupture phase while reaching the "break-in point" earlier.”

Reviewer comment 5:

Images are not clear. High quality images should be used.

Authors response:

In the paper, all drawings were prepared with the utmost care and attached in high resolution (600 dpi). The editors, however, in preparing versions of the file for reviewers, may have reduced the quality of the graphics regardless of their original high quality.

Author Response File: Author Response.doc