Micro-texture design criteria for cemented carbide ball-end milling cutters

2020 ◽  
Vol 34 (1) ◽  
pp. 127-136 ◽  
Author(s):  
Shucai Yang ◽  
Tianjiao Wang ◽  
Wei Ren ◽  
Shuai Su
Keyword(s):  
End Milling ◽  
Cemented Carbide ◽  
Design Criteria ◽  
Ball End Milling ◽  
Texture Design

Ball-End Milling of Cr12MoV Die Steel Using Ceramic Tool and Cements Carbide Tool

2012 ◽  
Vol 565 ◽  
pp. 466-471
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Zi Ye Liu ◽  
Xin Qiang Zhuang ◽  
Jun Wang
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Cutting Tools ◽  
Cutting Conditions ◽  
Cemented Carbide ◽  
Cutting Condition ◽  
Die Steel ◽  
Ball End Milling ◽  
Carbide Insert ◽  
Ceramic Insert

Ball-end milling of Cr12MoV die steel was studied using ceramic and cemented carbide inserts under different cutting conditions. The cutting forces, wear patterns and chip patterns generated using the different cutting tools at the different cutting conditions were investigated using a three component piezoelectric dynamometer and VHX-600E large depth-of-view 3-D scanner. The relationships among the cutting forces, wear patterns and chip patterns were discussed. The results indicated that the cutting forces caused by the ceramic insert were slightly lower than those caused by the cemented carbide insert under the same cutting conditions. For ceramic inserts, effects of cutting conditions on the rake face wear were different from those on the flank wear. The higher wear for the ceramic insert was caused at the lower cutting conditions but the higher wear for the cemented carbide insert was encountered at the higher cutting conditions. The squeezed chip was involved with the higher cutting forces. The sharper cutting edge of the cemented carbide insert was responsible for chip patterns caused by the No. I cutting condition. The effects of cutting conditions on wear patterns were more evident than that on chip patterns.

scholarly journals Multilayer Diamond Coatings Applied to Micro-End-Milling of Cemented Carbide

Materials ◽  
2021 ◽  
Vol 14 (12) ◽  
pp. 3333
Author(s):  
Eduardo L. Silva ◽  
Sérgio Pratas ◽  
Miguel A. Neto ◽  
Cristina M. Fernandes ◽  
Daniel Figueiredo ◽  
...  
Keyword(s):  
Electron Microscopy ◽  
End Milling ◽  
Interfacial Stress ◽  
Cemented Carbide ◽  
Air Cooling ◽  
Micro Machining ◽  
Diamond Coatings ◽  
Wear Properties ◽  
High Adhesion ◽  
Micro End Milling

Cobalt-cemented carbide micro-end mills were coated with diamond grown by chemical vapor deposition (CVD), with the purpose of micro-machining cemented carbides. The diamond coatings were designed with a multilayer architecture, alternating between sub-microcrystalline and nanocrystalline diamond layers. The structure of the coatings was studied by transmission electron microscopy. High adhesion to the chemically pre-treated WC-7Co tool substrates was observed by Rockwell C indentation, with the diamond coatings withstanding a critical load of 1250 N. The coated tools were tested for micro-end-milling of WC-15Co under air-cooling conditions, being able to cut more than 6500 m over a period of 120 min, after which a flank wear of 47.8 μm was attained. The machining performance and wear behavior of the micro-cutters was studied by scanning electron microscopy and energy-dispersive X-ray spectroscopy. Crystallographic analysis through cross-sectional selected area electron diffraction patterns, along with characterization in dark-field and HRTEM modes, provided a possible correlation between interfacial stress relaxation and wear properties of the coatings. Overall, this work demonstrates that high adhesion of diamond coatings can be achieved by proper combination of chemical attack and coating architecture. By preventing catastrophic delamination, multilayer CVD diamond coatings are central towards the enhancement of the wear properties and mechanical robustness of carbide tools used for micro-machining of ultra-hard materials.

Parameter Optimization of Ball End Milling Process on Inconel 718 Using RSM and TLBO Algorithm

2015 ◽  
Vol 15 (3) ◽  
pp. 293-300 ◽  
Author(s):  
Nandkumar N. Bhopale ◽  
Nilesh Nikam ◽  
Raju S. Pawade
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Ball End Milling

AbstractThis paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.

Mechanistic Modeling of the Ball End Milling Process for Multi-Axis Machining of Free-Form Surfaces

2000 ◽  
Vol 123 (3) ◽  
pp. 369-379 ◽  
Author(s):  
Rixin Zhu ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Mechanistic Modeling ◽  
Free Form ◽  
Surface Geometry ◽  
Workpiece Surface ◽  
Ball End Milling ◽  
Modeling Approach ◽  
Free Form Surfaces ◽  
Cutting Point

A mechanistic modeling approach to predicting cutting forces is developed for multi-axis ball end milling of free-form surfaces. The workpiece surface is represented by discretized point vectors. The modeling approach employs the cutting edge profile in either analytical or measured form. The engaged cut geometry is determined by classification of the elemental cutting point positions with respect to the workpiece surface. The chip load model determines the undeformed chip thickness distribution along the cutting edges with consideration of various process faults. Given a 5-axis tool path in a cutter location file, shape driving profiles are generated and piecewise ruled surfaces are used to construct the tool swept envelope. The tool swept envelope is then used to update the workpiece surface geometry employing the Z-map method. A series of 3-axis and 5-axis surface machining tests on Ti6A14V were conducted to validate the model. The model shows good computational efficiency, and the force predictions are found in good agreement with the measured data.

Geometrical Modeling of Tool-Workpiece Contact Zone and Chip Formation in Finish Ball End Milling Process with Tool Inclination Angles

2016 ◽  
Vol 693 ◽  
pp. 788-794
Author(s):  
Xiao Xiao Chen ◽  
Jun Zhao
Keyword(s):  
Contact Zone ◽  
Measurement Method ◽  
End Milling ◽  
Milling Process ◽  
Ball End Milling ◽  
Geometrical Modeling ◽  
Section Area ◽  
Inclination Angles ◽  
Area And Perimeter ◽  
End Milling Process

The tool-workpiece contact zone is an important issue in the ball end milling process. This paper investigated the effects of tool inclination angles on the tool-workpiece contact zone, and variations of the cutting section area and perimeter with the increasing tilt and lead angles were also analyzed by geometrical modeling and measurement method for ball end milling process. The appropriate tool inclination angles, which could avoid the extrusion and friction between tool tip and the uncut materials, shorten the loading time on the cutting flute, and decrease the maximum cutting forces, could be preferentially selected according to the distribution characteristics of the tool-workpiece contact zone and the variations of the cutting section area and perimeter corresponding to various tool postures.

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