High-speed milling surface topography dimensional analysis and wear prediction

2021 ◽  
Author(s):  
Wei Zhang ◽  
Kangning Li ◽  
Lei Zhang ◽  
Yonglei Sun
Keyword(s):  
Surface Topography ◽  
Dimensional Analysis ◽  
High Speed ◽  
Wear Prediction ◽  
High Speed Milling

scholarly journals A New Surface Topography-Based Method to Quantify Axial Error of High Speed Milling Cutters

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Wanqun Chen ◽  
Lei Lu ◽  
Wenkun Xie ◽  
Dehong Huo ◽  
Kai Yang
Keyword(s):  
Surface Topography ◽  
High Speed ◽  
Cutting Tool ◽  
Axial Direction ◽  
Machined Surface ◽  
High Rotational Speed ◽  
High Speed Milling ◽  
Tool Marks ◽  
Machined Surface Quality ◽  
Novel Method

Cutting tool rotation errors have significant influence on the machined surface quality, especially in micromilling. Precision metrology instruments are usually needed to measure the rotation error accurately. However, it is difficult to directly measure the axial error of micromilling tools due to the small diameters and ultra-high rotational speed. To predict the axial error of high speed milling tools in the actual machining conditions and avoid the use of expensive metrology instruments, a novel method is proposed in this paper to quantify the cutting tool error in the axial direction based on the tool marks generated on the machined surface. A numerical model is established to simulate the surface topography generation, and the relationship between tool marks and the cutting tool axial error is then investigated. The tool axial errors at different rotational speeds can be detected by the proposed method. The accuracy and the reliability of the proposed method are verified by machining experiments.

scholarly journals Multi Tooth Uneven Cutting Behavior of High-speed Milling Cutter and Criterion for Milled Surface Topography

2015 ◽  
Vol 9 (1) ◽  
pp. 395-401 ◽  
Author(s):  
Jiang Bin ◽  
Yao Guisheng ◽  
Zhang Shuai ◽  
Xu Tong
Keyword(s):  
Surface Topography ◽  
High Speed ◽  
Evaluation Method ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Characterization Methods ◽  
Response Characteristics ◽  
Milled Surface ◽  
Cutting Model ◽  
Cutting Behavior

With the cutting model of high-speed milling cutter in vibration condition, milling cutter vibration and effect of tooth error on cutting parameter are researched and high-speed milling cutter multi tooth uneven cutting behavior characterization methods are proposed. Use of high speed milling cutter cutting experiments and simulation results of surface topography, processing surface morphology characteristic parameters of cutter multi-tooth uneven cutting behavior response characteristics are revealed under the influence of milling cutter vibration and error, surface topography criterion is established in the cutting behavior of high speed milling cutter with multi-tooth, judgment method of multitooth uneven cutting behavior of high speed milling cutter with multi-tooth is proposed. Use the above criteria and evaluation method, reveal the formation mechanism of multi tooth uneven cutting, proposed compensation method of multi tooth uneven cutting behavior of high-speed milling cutter and do an experiment to verify the method.

Vibration Analysis of High-Speed End Milling Operations Applied to Injection Mold Materials

2017 ◽  
Author(s):  
Andris Logins ◽  
Toms Torims ◽  
Pedro Rosado Castellano ◽  
Santiago Gutiérrez ◽  
Rafael Torres
Keyword(s):  
Prediction Model ◽  
Surface Topography ◽  
High Speed ◽  
End Milling ◽  
Dynamical Behavior ◽  
Milling Process ◽  
Injection Mold ◽  
High Speed Milling ◽  
3D Surface Topography ◽  
End Milling Process

High-speed milling has often been applied in injection mold manufacturing processes, where surface roughness is a significant criterion in product quality demands. It is equally applicable to automotive or industrial engineering and to toy manufacturing, where plastic parts with a high-quality surface finish have been processed using the injection molding technique. High-speed milling involves a number of process parameters that may affect the 3D surface topography formation. Literature analysis reveals that dynamical behavior is a significant factor in the end milling process on surface roughness parameters. To improve the accuracy of predicted surface topography models, it is important to include the dynamical behavior of milling factor. This paper describes the surface prediction model of combined end-milling geometrical and dynamical interaction models. The natural frequency of machine assembly and forced vibrations during the cutting process were measured during the flat-end milling process. Unevenly distributed cutting marks were revealed by surface 3D topography images and microscopy images of the machined samples. A mathematical model to predict surface topography was developed, including dynamical behavior and cutting geometries. Machine accuracy also has to be addressed. 3D surface topography parameters from the experimental sample provided the results for the mathematical prediction model. This model offers a software tool for manufacturers to improve the quality of machined part surfaces, taking into account the behavioral properties of their machining equipment. Relevant conclusions about the manufacturing equipment accuracy have been drawn. Vibrations in the milling system affect the cutting process and contribute to the surface topography prediction model. Local cutting tool vibrations do not have any influence on surface parameter mean values.

Notch wear prediction model in high speed milling of AerMet100 steel with bull-nose tool considering the influence of stress concentration

Wear ◽  
2018 ◽  
Vol 408-409 ◽  
pp. 228-237 ◽  
Author(s):  
Haohao Zeng ◽  
Rong Yan ◽  
Pengle Du ◽  
Mingkai Zhang ◽  
Fangyu Peng
Keyword(s):  
Stress Concentration ◽  
Prediction Model ◽  
High Speed ◽  
Wear Prediction ◽  
High Speed Milling ◽  
Notch Wear

scholarly journals Analysis Method for Surface Topography Model in High Speed Milling Hardened Steel

2015 ◽  
Vol 9 (1) ◽  
pp. 219-225 ◽  
Author(s):  
Jiang Bin ◽  
Zhang Minghui ◽  
Wang Zhigang ◽  
Guan Yancong
Keyword(s):  
Surface Topography ◽  
High Speed ◽  
End Milling ◽  
Hardened Steel ◽  
Formation Condition ◽  
Machined Surface ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Contact Points ◽  
Milled Surface

During high speed milling hardened steel, the problem that tool vibration reducing machining surface quality causes led to a research for the influence characteristics of milled surface topography through high speed milling experiment. To determine the formation condition of milled surface topography, using displacement increment of origin of tool coordinate system which is caused by the milling cutter vibration and installation error, modifies the cutting motion trajectory. Based on the tool-workpiece contact relationship and the cutting layer parameters of contact points on two teeth, the residual units of machined surface are established, thereby proposing a solution method for the deformation and distribution characteristic of residual units under the overhanging volume and the vibration. Therefore, the milled surface topography of cutting hardness steel with high speed ball-end milling cutter is revealed to bring out a striking contrast between the simulation and experiment of milled surface topography of hardness steel.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Trochoidal machining for the high-speed milling of pockets

2016 ◽  
Vol 233 ◽  
pp. 29-43 ◽  
Author(s):  
Wu Shixiong ◽  
Ma Wei ◽  
Li Bin ◽  
Wang Chengyong
Keyword(s):  
High Speed ◽  
High Speed Milling
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