scholarly journals Milled Surface Affected by Damping Effect of Cross Edge and Flank Profiles of an End Mill

Procedia CIRP ◽  
2016 ◽  
Vol 46 ◽  
pp. 500-503
Author(s):  
Jeong Hoon Ko
Keyword(s):  
End Mill ◽  
Damping Effect ◽  
Milled Surface

Development of the cBN Electroplated End-Mill for High Precision Machining of CFRP

2020 ◽  
Author(s):  
Shinnosuke Yamashita ◽  
Tatsuya Furuki ◽  
Hiroyuki Kousaka ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
...  
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Drop Out ◽  
End Mill ◽  
Machined Surface ◽  
Side Milling ◽  
Reinforced Plastics ◽  
Milled Surface ◽  
Grinding Conditions ◽  
Grinding Tool

Abstract Recently, the demand of carbon fiber reinforced plastics (CFRP) has been rapidly increased in various fields. In most cases, CFRP products requires a finish machining like cutting or grinding. In the case of an end-milling, burrs and uncut fibers are easy to occur. On the other hand, a precise machined surface and edge will be able to obtain by using the grinding tool. Therefore, this research has been developed a novel the cBN electroplated end-mill that combined end-mill and grinding tool. In this report, the effectiveness of developed tool was investigated. First, the developed tool cut the CFRP with side milling. As the result, the cBN abrasives that were fixed on the outer surface of developed tool did not drop out. Next, the end-milled surface of CFRP was ground with the developed tool under several grinding conditions based on the Design of Experiment. Consequently, the optimum grinding condition that can obtain the sharp edge which does not have burrs and uncut fibers was found. However, surface roughness was not good enough. Thus, an oscillating grinding was applied. In addition, the theoretical surface roughness formula in case using the developed tool was formularized. As the result, the required surface roughness in the airplane field was obtained.

The Effect of Tool Flexibility on Back-Cutting in End Milled Surfaces

1999 ◽  
Vol 121 (3) ◽  
pp. 532-537 ◽  
Author(s):  
S. N. Melkote ◽  
J. W. Sutherland ◽  
C. King
Keyword(s):  
Cutting Force ◽  
Surface Texture ◽  
Surface Characteristics ◽  
End Mill ◽  
Force System ◽  
Feed Force ◽  
Milled Surface ◽  
Cutting Effect ◽  
Surface Profiles ◽  
Good Agreement

End milled surface texture is inhomogeneous and often exhibits complex lay patterns. An important contributing factor to these surface characteristics is the back-cutting effect. This effect causes cutter tooth mark patterns on the surface in the forward and reverse tool feed directions. In this paper, the dependence of back-cutting on end mill flexibility and its influence on the slot floor surface texture are modeled and experimentally verified. It is shown that the extent to which tool flexibility affects back-cutting is determined by the resultant cutting force system and not the feed force alone. The variation in the amount of back-cutting typically observed across the width of a milled slot is also explained by this model. The model, although simple in form, yields reasonably good agreement with the measured surface profiles.

Cutting Performance Comparison of Bonded and Brazed End Mills

1985 ◽  
Vol 107 (2) ◽  
pp. 153-158 ◽  
Author(s):  
L. S. Zhang ◽  
M. M. Sadek ◽  
D. H. Wale
Keyword(s):  
Performance Comparison ◽  
Bond Line ◽  
Cutting Performance ◽  
End Mill ◽  
Metallic Particles ◽  
Damping Effect ◽  
Bonding Material ◽  
Bond Layer ◽  
End Mills ◽  
Bonding Technique

In this paper the feasibility of fabricating spiral carbide tipped end mill adhesive using bonding technique has been investigated. Cutting tests were performed and cutting forces, vibrational motion, tool wear, and surface roughness were measured. The cutting performance of the bonded end mill has been assessed in relation to those of the brazed tool. This investigation shows that the performance of the bonded end mills is almost identical to that of the commercially available brazed ones in both cases of normal cutting conditions with and without coolant. The vibration characteristics show that the damping effect of the bond layer is insignificant due to dimensions and geometry of the bond line. Infrared prints demonstrate a pronounced heat isolation due to the low thermal conductivity of the adhesive, which can be improved by mixing metallic particles in the bonding material.

scholarly journals Analysis of machining-induced residual stresses of milled aluminum workpieces, their repeatability, and their resulting distortion

2021 ◽  
Author(s):  
Daniel Weber ◽  
Benjamin Kirsch ◽  
Christopher R. Chighizola ◽  
Christopher R. D’Elia ◽  
Barbara S. Linke ◽  
...  
Keyword(s):  
Residual Stresses ◽  
Cutting Speed ◽  
Past Research ◽  
Hole Drilling ◽  
Statistical Confidence ◽  
Measured Stress ◽  
Main Driver ◽  
Milled Surface ◽  
Force Signal ◽  
Repeatability Standard Deviation

AbstractMachining-induced residual stresses (MIRS) are a main driver for distortion of thin-walled monolithic aluminum workpieces. Before one can develop compensation techniques to minimize distortion, the effect of machining on the MIRS has to be fully understood. This means that not only an investigation of the effect of different process parameters on the MIRS is important. In addition, the repeatability of the MIRS resulting from the same machining condition has to be considered. In past research, statistical confidence of MIRS of machined samples was not focused on. In this paper, the repeatability of the MIRS for different machining modes, consisting of a variation in feed per tooth and cutting speed, is investigated. Multiple hole-drilling measurements within one sample and on different samples, machined with the same parameter set, were part of the investigations. Besides, the effect of two different clamping strategies on the MIRS was investigated. The results show that an overall repeatability for MIRS is given for stable machining (between 16 and 34% repeatability standard deviation of maximum normal MIRS), whereas instable machining, detected by vibrations in the force signal, has worse repeatability (54%) independent of the used clamping strategy. Further experiments, where a 1-mm-thick wafer was removed at the milled surface, show the connection between MIRS and their distortion. A numerical stress analysis reveals that the measured stress data is consistent with machining-induced distortion across and within different machining modes. It was found that more and/or deeper MIRS cause more distortion.

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