Effect of geometric feature and cutting direction on variation of force and vibration in high-speed milling of TC4 curved surface

When the pocket in die and mould is machined by high speed milling (HSM), the cutting forces increase and vibration fluctuates at the pocket corner because of the sudden change of cutting direction in general. It will cause serious wear and possible breakage of cutting tool, and poor quality of parts. By means of experiments, the cutting forces and vibration at the pocket corner with different HSM conditions are measured. The results show that the sharper pocket corner, higher cutting speeds, larger feed rate per tooth and radial depth of cut, will result in increasing of cutting forces and vibration amplitude. Thus, it will lead to be unstable during the process of high speed milling pocket corner.

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Stability recognition for high-speed milling of TC4 thin-walled parts with curved surface

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-016-9905-5 ◽

2017 ◽

Vol 91 (5-8) ◽

pp. 2819-2829 ◽

Cited By ~ 4

Author(s):

Jian-wei Ma ◽

Zhen Liu ◽

Zhen-yuan Jia ◽

De-ning Song ◽

Yuan-yuan Gao ◽

...

Keyword(s):

High Speed ◽

Curved Surface ◽

High Speed Milling ◽

Thin Walled

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Tool path planning and machining deformation compensation in high-speed milling for difficult-to-machine material thin-walled parts with curved surface

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-015-7825-4 ◽

2015 ◽

Vol 84 (9-12) ◽

pp. 1757-1767 ◽

Cited By ~ 39

Author(s):

Yuan-yuan Gao ◽

Jian-wei Ma ◽

Zhen-yuan Jia ◽

Fu-ji Wang ◽

Li-kun Si ◽

...

Keyword(s):

Path Planning ◽

High Speed ◽

Tool Path ◽

Curved Surface ◽

Tool Path Planning ◽

Machine Material ◽

High Speed Milling ◽

Machining Deformation ◽

Thin Walled ◽

Deformation Compensation

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Study of machining parameter optimization in high speed milling of Inconel 718 curved surface based on cutting force

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-014-6115-x ◽

2014 ◽

Vol 75 (1-4) ◽

pp. 269-277 ◽

Cited By ~ 13

Author(s):

Jian-wei Ma ◽

Fu-ji Wang ◽

Zhen-yuan Jia ◽

Qiang Xu ◽

Yan-yu Yang

Keyword(s):

Cutting Force ◽

Parameter Optimization ◽

Inconel 718 ◽

High Speed ◽

Curved Surface ◽

High Speed Milling ◽

Machining Parameter

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Influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405417716495 ◽

2017 ◽

Vol 233 (1) ◽

pp. 18-30 ◽

Cited By ~ 6

Author(s):

Jian-wei Ma ◽

Zhen-yuan Jia ◽

Guang-zhi He ◽

Zhen Liu ◽

Xiao-xuan Zhao ◽

...

Keyword(s):

Tool Wear ◽

Cutting Force ◽

Tool Life ◽

Inconel 718 ◽

High Speed ◽

Cutting Tool ◽

Helix Angle ◽

Curved Surface ◽

Geometrical Parameters ◽

High Speed Milling

High-speed machining provides an efficient approach for machining Inconel 718 with high quality and high efficiency. For high-speed milling of Inconel 718 curved surface, the geometrical characteristics are changing continuously leading to a sharp fluctuation of cutting force, which will aggravate the tool wear. As the wear mechanism of coated cutting tool is seriously affected by the cutting tool geometrical parameters, suitable geometrical parameters of cutting tool should be selected to avoid the cutting tool from being worn out very quickly. In this study, the influence of cutting tool geometrical parameters on tool wear in high-speed milling of Inconel 718 curved surface is investigated with coated cutting tool, and the cutting force in milling process is also analyzed. The results show that the cutting force variation can manifest the tool wear degree, and the failure type of coated cutting tool in plane milling and curved surface milling after the same cutting length is different. Furthermore, the cutting tool geometrical parameters seriously affect the tool wear and the tool life in high-speed milling of Inconel 718 curved surface. Concretely, the small rake angle has greater strength and has superiority, the relief angle increasing can enhance the tool life, and the tool life is decreased with the increasing of helix angle for the cutting tool, whose helix angle is larger than 30°. This study provides a theoretical basis for cutting tool wear mechanism and cutting tool geometrical parameter selection in high-speed milling of Inconel 718 curved surface, so as to guarantee the machining efficiency in high-speed milling of Inconel 718 curved surface.

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Influence of spindle speed on tool wear in high-speed milling of Inconel 718 curved surface parts

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405416668925 ◽

2016 ◽

Vol 232 (8) ◽

pp. 1331-1341 ◽

Cited By ~ 1

Author(s):

Jianwei Ma ◽

Yuanyuan Gao ◽

Zhenyuan Jia ◽

Dening Song ◽

Likun Si

Keyword(s):

Tool Wear ◽

Cutting Force ◽

Inconel 718 ◽

High Speed ◽

Spindle Speed ◽

Curved Surface ◽

Machining Efficiency ◽

High Speed Milling ◽

Coated Tool ◽

Curved Surface Parts

High-speed milling, which provides an efficient approach for high-quality machining, is widely adopted for machining difficult-to-machine materials such as Inconel 718. For high-speed milling of Inconel 718 curved surface parts, the spindle speed which determines cutting speed directly is regarded as an important cutting parameter related to tool wear and machining efficiency. Meanwhile, because of the changing geometric features of curved surface, cutting force is changing all the time with the variation of geometric features, which influences not only tool wear but also machining quality significantly. In this study, the influence of spindle speed on coated tool wear in high-speed milling of Inconel 718 curved surface parts is studied through a series of experiments on considering tool life, cutting force, cutting force fluctuation, and machining efficiency. According to the experimental results, the appropriate spindle speed that can balance both the tool life and the machining efficiency is selected as 10,000 r/min for high-speed milling of Inconel 718 curved surface parts. In addition, the coated tool wear mechanism is investigated through scanning electron microscopy–energy dispersive x-ray spectroscopy analysis. The results show that at the beginning wear stage and the stable wear stage, the coated tool wear is mainly caused by mechanical wear. Then, with the increasing cutting temperature due to the blunt tool edge, the tool wear becomes compound wear which contains more than one wear form so as to cause a severe tool wear.

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