Supervision of Tool Wear and Surface Quality During End Milling Operations

Tool wear is easy occurred in titanium alloy milling process which will affect the surface quality. Surface roughness and surface morphology as an important index to describe and evaluate the surface quality has a great influence on service performance. Therefore, the study on the effect of tool wear on surface qualities is important to improve the surface integrity of titanium alloy parts. Cutting radius of ball-end milling cutter is solved to analyze the effect of tool wear on the cutting radius. The tool wear and the surface qualities of TC4 are achieved through wear experiment. And then the influence law of tool wear on surface qualities and chip morphology are analyzed. The results show that surface roughness value decrease firstly and then increases and that chip morphology with flank wear increase from the unit chip to the serrated chip.

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Machinability study of aircraft series aluminium alloys 7075-T6 and 7050-T7451

Transactions of the Canadian Society for Mechanical Engineering ◽

10.1139/tcsme-2019-0215 ◽

2020 ◽

Vol 44 (3) ◽

pp. 427-439

Author(s):

Ali Yeganefar ◽

Seyed Ali Niknam ◽

Victor Songmene

Keyword(s):

Aluminium Alloy ◽

Surface Quality ◽

Aluminium Alloys ◽

End Milling ◽

Experimental Studies ◽

Burr Formation ◽

Limited Information ◽

Milling Operations ◽

Aluminium Alloy 7050 ◽

Machining Operations

The aluminium alloy 7050-T7451 is generally considered as the principal choice in aeronautical applications demanding adequate strength, stress corrosion cracking resistance, and toughness. Surprisingly, despite extensive research works on machining and machinability of aluminium alloys, including aluminium alloy 7075-T6, limited information was found on machining and machinability evaluation of 7050-T7451, which belongs to a similar family as 7075-T6. To remedy the lack of knowledge determined, dry ball-end milling operations were performed with coated end milling tools on both materials. Experimental characterization and cutting force measurements were performed to measure/evaluate the cutting forces, burr formation morphology, insert performance (wear/breakage), and surface quality attributes. According to experimental studies, 7050-T7451 was found more machinable than 7075-T6. Less burr formation and better surface quality were observed on 7075-T6. Machining attributes are influenced by different experimental factors. However, other machinability attributes, including residual stress, vibration modes, as well as particle emission, must be studied under various lubrication modes and machining operations in subsequent studies. This also recalls further studies on simultaneous multiple response optimization.

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Application of tri-hybridized carbonaceous nanocutting fluids in an end milling operation by the minimum quantity lubrication technique

Proceedings of the Institution of Mechanical Engineers Part J Journal of Engineering Tribology ◽

10.1177/13506501211043859 ◽

2021 ◽

pp. 135065012110438

Author(s):

S. Vignesh ◽

U. Mohammed Iqbal

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

End Milling ◽

Hexagonal Boron Nitride ◽

Coconut Oil ◽

Minimum Quantity Lubrication ◽

Work Piece ◽

Cutting Fluids ◽

Minimum Quantity ◽

Milling Operations

This paper is concentrated on the exploration of carbonaceous nanocutting fluids with the concept of tri-hybridization with improved lubricative and cooling properties by using multi-walled carbon nanotubes, hexagonal boron nitride , and graphene nanoparticles with neat cold-pressed coconut oil in a fixed volumetric proportion. The rheological properties of the nanofluids were studied to assess their performance in real-time end milling operations using an AA7075 work piece on a CNC lathe machine under a minimum quantity lubrication environment. At the outset, the carbonaceous nanofluids gave good performance when compared to conventional cutting fluids. Furthermore, the surfaces of the tribo-pairs and the chips formed were analyzed using a profilometer and high-end microscopes. The results obtained from the experiments confirm that the tri-hybridized carbonaceous nanolubricant has reduced the cutting force, tool wear, and surface roughness when correlated to monotype nanofluids. The scanning electron microscope images of the surface and tool were studied and it was found that the surface quality was maintained while end milling with tri-hybridized carbonaceous nanofluid. Improvement of ∼17%, 20% and 25% in cutting forces, surface roughness and tool wear was found in tri-hybrid fluid when compared to other fluids. Thus, the present work indicates that the addition of carbon-based nanoparticles with coconut oil has offered better performance and is found to be a credible alternative to existing conventional cutting fluids.

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Prediction of cutting force, tool wear and surface roughness of Al6061/SiC composite for end milling operations using RSM

Journal of Mechanical Science and Technology ◽

10.1007/s12206-013-0729-z ◽

2013 ◽

Vol 27 (9) ◽

pp. 2813-2822 ◽

Cited By ~ 37

Author(s):

S. Jeyakumar ◽

K. Marimuthu ◽

T. Ramachandran

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Cutting Force ◽

End Milling ◽

Milling Operations

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Investigating the Design of Condition Monitoring Systems to Evaluate Surface Roughness under the Variability in Tool Wear and Fixturing Conditions

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.572.467 ◽

2013 ◽

Vol 572 ◽

pp. 467-470 ◽

Cited By ~ 1

Author(s):

Jabbar Abbas ◽

Amin Al-Habaibeh ◽

Dai Zhong Su

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Condition Monitoring ◽

End Milling ◽

Milling Operations ◽

Different Types ◽

Machined Parts ◽

Condition Monitoring Systems ◽

Condition Monitoring System

Surface finish of machined parts in end milling operations is significantly influenced by process faults such as tool wear and tool holding (fixturing system). Therefore, monitoring these faults is considerably important to improve the quality of the product. In this paper, an investigation is presented to design the condition monitoring system to evaluate the surface roughness of the workpiece under effects of gradual tool wear and different types of the fixturing system. Automated Sensor and Signal Processing Selection (ASPS) approach is implemented and tested to determine the sensitivity of the sensory signals to estimate surface roughness under the variable conditions in comparison to surface roughness measurement device. The results indicate that the system is capable of detection the change and the trend in surface roughness. However, the sensitive features are found to be different based on the change in the fixturing system.

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Influence of Cutting Conditions on Surface and Sub-Surface Quality of High Speed Dry End Milling Ti-6Al-4V

Jurnal Teknologi ◽

10.11113/jt.v67.2776 ◽

2014 ◽

Vol 67 (3) ◽

Cited By ~ 1

Author(s):

H. Safari ◽

S. Izman

Keyword(s):

Plastic Deformation ◽

Tool Wear ◽

Surface Quality ◽

High Speed ◽

End Milling ◽

Cutting Parameters ◽

Machining Process ◽

Surface Alteration ◽

Cutting Speeds

Surface quality is one of the most critical restraints for determining cutting parameters and selecting of machining process in metal cutting process. In this study, the effects of cutting parameters and tool wear on the surface and sub-surface quality of high speed dry end milling Ti-6Al-4V were investigated. PVD Coated carbide tools were used under different high cutting speeds and feed rates. The quality of the machined surface and corresponding alteration on the sub-surface and entry/exit edges were characterized through scanning electron microscopy. The results showed that the better surface quality was obtained when machining at higher cutting speeds and feed rates. High speed dry end milling using the worn tool causes to plastic deformation of the alloy which is resulted in developing the lamellae on the surface and causing poor surface finish. Worn tools with the uniform tool wear land generated better surface quality compare to those with chipping and flaking on the tool edge surface. Tool wear is suggested as the other contributing factor in developing entry and exit edge damages. The results of sub-surface alteration measurement revealed that the worn tool enhanced the sub-surface alteration resulted in 45% increase in plastic deformation compare to the new tool.

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Tool Wear Progression and Optimization in End Milling of AISI 316 Stainless Steel

Materials Science Forum ◽

10.4028/www.scientific.net/msf.1013.33 ◽

2020 ◽

Vol 1013 ◽

pp. 33-40

Author(s):

Peter Babatunde Odedeyi ◽

Khaled Abou-El-Hossein

Keyword(s):

Stainless Steel ◽

Tool Wear ◽

Surface Quality ◽

Tool Life ◽

High Performance ◽

End Milling ◽

Depth Of Cut ◽

Feed Speed ◽

Aisi 316 ◽

Coated Carbide

The high-performance machining of difficult-to-cut stainless steel (AISI 316) demands the development and optimization of high-performance tools that can withstand tool load without compromising the surface quality of the components been produced. To justify the optimization feasibility of coated carbide tool in end milling application for good surface quality, a material removal and Productivity approach by evaluating the tool life under optimized cutting condition were carried out in this current research. The objective of this study is to optimize flank tool wear in end milling of AISI 316 using Design of Experiment and box-Behnken method. Tool wear value of 0.174mm was achieved through optimization at low values of feed, speed, and depth of cut. However, an increased feed, depth of cut and speed promised to yield better volume removed in return making tool life to be truncated faster.

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