Chip temperature and its effects on chip morphology, cutting forces, and surface roughness in high-speed face milling of hardened steel

2014 ◽  
Vol 77 (9-12) ◽  
pp. 2209-2219 ◽  
Author(s):  
Xiaobin Cui ◽  
Jingxia Guo ◽  
Jun Zhao ◽  
Yanyan Yan
Keyword(s):  
Surface Roughness ◽  
Cutting Forces ◽  
High Speed ◽  
Chip Morphology ◽  
Hardened Steel ◽  
Face Milling ◽  
Chip Temperature ◽  
On Chip

Experimental Study of the Corner of Hardened Steel Mould in High Speed Milling with Micro-End Mill

2014 ◽  
Vol 800-801 ◽  
pp. 9-14
Author(s):  
Bang Xi Dong ◽  
Ying Ning Hu ◽  
Shan Shan Hu ◽  
Xi Huang
Keyword(s):  
Surface Roughness ◽  
Cutting Forces ◽  
High Speed ◽  
Great Influence ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Micro End Mill ◽  
Steel Mould

High speed machining of the corner of hardened steel mould has a great influence to the entire product performance of the mould. In this paper, with the single factor experiments, the influence of feed per tooth, cutting speed and angle of the corner to the cutting forces, the vibration value and the surface roughness were analyzed. And the cutting parameters were optimized. The cutting forces, vibration value and surface roughness value of the corner of the mould reached the minimum value when the cutting speed was 80 m/min and the feed per tooth was 0.006 mm/z in the experiment. The surface quality of corner with angle of 90o was better than the corner with angle of 60o and 120o with various milling parameters.

Experimental study on the chip morphology, tool–chip contact length, workpiece vibration, and surface roughness during high-speed face milling of A6061 aluminum alloy

2019 ◽  
Vol 234 (3) ◽  
pp. 610-620 ◽  
Author(s):  
Thi-Hoa Pham ◽  
Duc-Toan Nguyen ◽  
Tien-Long Banh ◽  
Van-Canh Tong
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Contact Length ◽  
Face Milling ◽  
Cutting Conditions ◽  
Workpiece Vibration

In this study, experiments of high-speed face milling of A6061 aluminum alloy with a carbide insert milling cutter under dry cutting conditions were conducted. The contact length between tool and chip, the workpiece vibration amplitude, and the arithmetic average surface roughness were measured under varying cutting conditions (cutting speed, feed rate, and depth of cut). The characteristics of chip morphology were observed using scanning electron microscope. Experimental results showed that the increasing cutting speed reduced the tool–chip contact length, the workpiece vibration, and the surface roughness. The tool–chip contact length, the workpiece vibration, and the surface roughness were all increased with increasing cutting depth and feed rate. The results of chip morphology showed that the chips with serrated form were generated under high-speed cutting conditions. Moreover, scratch lines, plastic deformation cavities, and local molten chip material were observed on the slide chip surface.

Predicting the High Speed Cutting Process of Titanium Alloy by Finite Element Method

2011 ◽  
Author(s):  
Xiangqin Zhang ◽  
Xueping Zhang ◽  
A. K. Srivastava
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Process ◽  
Fe Model ◽  
Dry Cutting ◽  
Friction Coefficients ◽  
Machining Conditions

To predict the cutting forces and cutting temperatures accurately in high speed dry cutting Ti-6Al-4V alloy, a Finite Element (FE) model is established based on ABAQUS. The tool-chip-work friction coefficients are calculated analytically using the measured cutting forces and chip morphology parameter obtained by conducting the orthogonal (2-D) machining tests. It reveals that the friction coefficients between tool-work are 3∼7 times larger than that between tool-chip, and the friction coefficients of tool-chip-work vary with feed rates. The analysis provides a better reference for the tool-work-chip friction coefficients than that given by literature empirically regardless of machining conditions. The FE model is capable of effectively simulating the high speed dry cutting process of Ti-6Al-4V alloy based on the modified Johnson-Cook model and tool-work-chip friction coefficients obtained analytically. The FE model is further validated in terms of predicted forces and the chip morphology. The predicted cutting force, thrust force and resultant force by the FE model agree well with the experimentally measured forces. The errors in terms of the predicted average value of chip pitch and the distance between chip valley and chip peak are smaller. The FE model further predicts the cutting temperature and residual stresses during high speed dry cutting of Ti-6Al-4V alloy. The maximum tool temperatures exist along the round tool edge, and the residual stress profiles along the machined surface are hook-shaped regardless of machining conditions.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

Theoretical Surface Roughness Model in High Speed Face Milling

2014 ◽  
Vol 989-994 ◽  
pp. 3331-3334
Author(s):  
Tao Zhang ◽  
Guo He Li ◽  
L. Han
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Parameters ◽  
Angular Speed ◽  
Face Milling ◽  
Advanced Manufacturing ◽  
Roughness Model ◽  
Machined Parts ◽  
Important Object

High speed milling is a newly developed advanced manufacturing technology. Surface integrity is an important object of machined parts. Surface roughness is mostly used to evaluate to the surface integrity. A theoretical surface roughness model for high face milling was established. The influence of cutting parameters on the surface roughness is analyzed. The surface roughness decreases when the cutter radius increases, total number of tooth and rotation angular speed, while it increases with the feeding velocity. The high speed face milling can get a smooth surface and it can replace the grinding with higher efficiency.

scholarly journals Thermographic Study of Chip Temperature in High-Speed Dry Milling Magnesium Alloys

2016 ◽  
Vol 7 (2) ◽  
pp. 86-92 ◽  
Author(s):  
Józef Kuczmaszewski ◽  
Ireneusz Zagórski ◽  
Piotr Zgórniak
Keyword(s):  
Temperature Measurement ◽  
Magnesium Alloys ◽  
High Speed ◽  
Machining Process ◽  
Dry Milling ◽  
Technological Parameters ◽  
Chip Temperature ◽  
Thermographic Study ◽  
On Chip ◽  
The Impact

Abstract This paper presents an overview of the state of knowledge on temperature measurement in the cutting area during magnesium alloy milling. Additionally, results of own research on chip temperature measurement during dry milling of magnesium alloys are included. Tested magnesium alloys are frequently used for manufacturing elements applied in the aerospace industry. The impact of technological parameters on the maximum chip temperature during milling is also analysed. This study is relevant due to the risk of chip ignition during the machining process.

Research on Surface Roughness Prediction Model for High-Speed Milling Inclined Plane of Hardened Steel

2010 ◽  
Vol 97-101 ◽  
pp. 2044-2048 ◽  
Author(s):  
Yuan Ling Chen ◽  
Bao Lei Zhang ◽  
Wei Ren Long ◽  
Hua Xu
Keyword(s):  
Surface Roughness ◽  
Prediction Model ◽  
High Speed ◽  
Hardened Steel ◽  
Prediction Errors ◽  
Inclined Plane ◽  
Workpiece Surface ◽  
Factors Influencing ◽  
Generalized Regression Neural Networks ◽  
Roughness Prediction

As the factors influencing the workpiece surface roughness is complexity and uncertainty, according to orthogonal experimental results, the paper established Empirical regression prediction model and generalized regression neural networks (GRNN) for prediction of surface roughness when machining inclined plane of hardened steel in high speed , moreover, compared their prediction errors. The results show that GRNN model has better prediction accuracy than empirical regression prediction model and can be better used to control the surface roughness dynamically.

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