Chatter Behavior in the Milling Process of Inconel 718: Effects of Tool Edge Radius

Inconel 718 is widely used in various high end industries such as aerospace, nuclear plant, petrochemical plants etc. Inconel 718 is used for these applications due to unique mechanical properties such as high mechanical strength at elevated temperatures, high resistance to corrosion, and high strength to weight ratio. The unique properties of Inconel 718 made it difficult to be machined due to rapid work hardening and high cutting temperature. In addition, chatter vibration further increases the difficulty in machining of Inconel 718. In this paper, an experimental study on the effects of tool edge radius to the chatter behaviour was investigated. The dynamic responses of the milling process were recorded and analysed in both time domain and frequency domain. The results showed the variable helix and pitch end mill tool with larger tool edge radius able to mitigate chatter vibration at lower cutting speeds. Variable helix and pitch end mill with specific tool edge radius able to mitigate chatter vibration under the same cutting parameters. Experiments shows proper selection of tool edge radius improves the stability of end milling machining process.

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An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining

Journal of Manufacturing Science and Engineering ◽

10.1115/1.2162905 ◽

2005 ◽

Vol 128 (2) ◽

pp. 474-481 ◽

Cited By ~ 148

Author(s):

X. Liu ◽

R. E. DeVor ◽

S. G. Kapoor

Keyword(s):

Analytical Model ◽

Chip Thickness ◽

Machining Process ◽

Thickness Effect ◽

Uncut Chip Thickness ◽

Minimum Chip Thickness ◽

Tool Edge Radius ◽

Edge Radius ◽

Tool Edge ◽

Cutting Velocity

In micromachining, the uncut chip thickness is comparable or even less than the tool edge radius and as a result a chip will not be generated if the uncut chip thickness is less than a critical value, viz., the minimum chip thickness. The minimum chip thickness effect significantly affects machining process performance in terms of cutting forces, tool wear, surface integrity, process stability, etc. In this paper, an analytical model has been developed to predict the minimum chip thickness values, which are critical for the process model development and process planning and optimization. The model accounts for the effects of thermal softening and strain hardening on the minimum chip thickness. The influence of cutting velocity and tool edge radius on the minimum chip thickness has been taken into account. The model has been experimentally validated with 1040 steel and Al6082-T6 over a range of cutting velocities and tool edge radii. The developed model has then been applied to investigate the effects of cutting velocity and edge radius on the normalized minimum chip thickness for various carbon steels with different carbon contents and Al6082-T6.

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Analyzing the effect of tool edge radius on cutting temperature in micro-milling process

10.1117/12.867961 ◽

2010 ◽

Author(s):

Y. C. Liang ◽

K. Yang ◽

K. N. Zheng ◽

Q. S. Bai ◽

W. Q. Chen ◽

...

Keyword(s):

Cutting Temperature ◽

Milling Process ◽

Micro Milling ◽

Tool Edge Radius ◽

Edge Radius ◽

Tool Edge

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The effects of tool edge radius on drill deflection and hole misalignment in deep hole gundrilling of Inconel-718

CIRP Annals ◽

10.1016/j.cirp.2014.03.075 ◽

2014 ◽

Vol 63 (1) ◽

pp. 125-128 ◽

Cited By ~ 17

Author(s):

K.S. Woon ◽

A. Chaudhari ◽

M. Rahman ◽

S. Wan ◽

A. Senthil Kumar

Keyword(s):

Inconel 718 ◽

Deep Hole ◽

Tool Edge Radius ◽

Edge Radius ◽

Tool Edge

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Finite Element Modeling for High Speed Machining of Ti-6Al-4V Using ALE Boundary Technology

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.66-68.1509 ◽

2011 ◽

Vol 66-68 ◽

pp. 1509-1514

Author(s):

Dong Lu ◽

Ming Ming Yang ◽

Hong Fu Huang ◽

Xiao Hong Zhong

Keyword(s):

Finite Element ◽

Finite Element Model ◽

High Speed ◽

Element Model ◽

Machining Process ◽

Computational Time ◽

High Speed Machining ◽

Tool Edge Radius ◽

Edge Radius ◽

Tool Edge

A finite element model of HSM (High Speed Machining) process of Ti6Al4V was developed with Abaqus 6.10. The flow stress of Ti6Al4V is taken as a function of strain, strain rate and temperature. Considering the fact that the tool edge radius is relatively large in HSM of Ti6Al4V and significantly influences the mechanical behaviour, thus a new Arbitrary Lagrangian-Eulerian (ALE) boundary technology was incorporated into the finite element model to simulate the flowing material around the tool edge.The adoption of ALE boundary technology could avoid using the traditional chip separation criterias and element deletion method in the model, which at the same time results in the less excessive element distortion and computational time in comparison with traditional finite element models of cutting process. The simulation results of Cutting force and temperature close to the experimental values in an acceptable range could be obtained and a stagnant zone in front of the tool edge was successfully observed in this new developed model with large tool edge radius.

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FE analysis on the association between tool edge radius and thermal-mechanical load in machining Inconel 718

Procedia CIRP ◽

10.1016/j.procir.2021.09.016 ◽

2021 ◽

Vol 102 ◽

pp. 91-96

Author(s):

Yang Liu ◽

Andrii Hrechuk ◽

Mathias Agmell ◽

Aylin Ahadi ◽

Jan-Eric Stahl ◽

...

Keyword(s):

Inconel 718 ◽

Mechanical Load ◽

Fe Analysis ◽

Tool Edge Radius ◽

Edge Radius ◽

Tool Edge

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Effects of tool edge radius and rake angle on ductile machining process of CaF2

International Journal of Nanomanufacturing ◽

10.1504/ijnm.2011.042476 ◽

2011 ◽

Vol 7 (3/4) ◽

pp. 350 ◽

Cited By ~ 1

Author(s):

Mingjun Chen ◽

Wenbin Jiang ◽

Mingquan Li

Keyword(s):

Rake Angle ◽

Machining Process ◽

Tool Edge Radius ◽

Edge Radius ◽

Ductile Machining ◽

Tool Edge

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Finite Element Analysis of Micro-Cutting Aluminum 7050-T7451 with the Tool Edge Radius Considered

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.443.663 ◽

2010 ◽

Vol 443 ◽

pp. 663-668 ◽

Cited By ~ 1

Author(s):

Jun Zhou ◽

Jian Feng Li ◽

Jie Sun

Keyword(s):

Finite Element ◽

Plastic Strain ◽

Cutting Temperature ◽

Machining Process ◽

Micro Machining ◽

Element Analysis ◽

Micro Cutting ◽

Tool Edge Radius ◽

Edge Radius ◽

Tool Edge

In this paper, a series of simulation works by finite element method for predicting the temperature and the plastic strain distributions in micro cutting process with the tool edge radius considered were conducted. The workpiece is Aluminum alloy 7050-T7451 and its flow stress is taken as a function of strain, strain rate and temperature in order to reflect realistic behavior in machining process. From the simulation works, a lot of information on the micro-machining process can be obtained, such as cutting force, cutting temperature, distributions of temperature and plastic strain, etc. In addition, explanations for the observed trends are also given.

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Tool edge radius effect on cutting temperature in micro-end-milling process

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-010-2795-z ◽

2010 ◽

Vol 52 (9-12) ◽

pp. 905-912 ◽

Cited By ~ 49

Author(s):

Kai Yang ◽

Ying-chun Liang ◽

Kang-ning Zheng ◽

Qing-shun Bai ◽

Wan-qun Chen

Keyword(s):

End Milling ◽

Cutting Temperature ◽

Milling Process ◽

Tool Edge Radius ◽

Edge Radius ◽

Tool Edge ◽

Micro End Milling ◽

End Milling Process

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Mechanism of Variable Helix Tools in Suppressing Chatter Using Process Damping for Machining Titanium Alloys at Low Cutting Speed

Materials Science Forum ◽

10.4028/www.scientific.net/msf.773-774.370 ◽

2013 ◽

Vol 773-774 ◽

pp. 370-376

Author(s):

Muhammad Adib Shaharun ◽

Ahmad Razlan Yusoff ◽

Mohammad S. Reza

Keyword(s):

Titanium Alloy ◽

Cutting Speed ◽

Milling Process ◽

Cutting Process ◽

Chatter Vibration ◽

Process Damping ◽

High Cutting Speed ◽

Titanium Machining ◽

Different Types ◽

Variable Helix

Titanium is difficult-to-cut materials due to its poor machinability and thermal conductivity when machining at high cutting speed. To overcome this machining titanium alloy problem, this study in interaction between machining structural system and the cutting process are very important. One of the main problems in the cutting process is chatter vibration. Due to chatter problem, the mechanism to suppress chatter named, process damping is a useful method can be manipulated to improve the limited productivity of titanium machining at low speed machining in milling process. In the present study, experiment are conducted to evaluate and study the process damping mechanism in milling using different types of variable tools geometries. These tools are variable he-lix/uniform pitch, variable pitch/uniform helix and variable helix and pitch and uniform helix/pitch. The result showed that the variable helix and pitch tools is very significantly improve process damping performance in machining titanium alloy compare to traditional of regular tools and other irregular tools.

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Simulation of Meso-Scale Machining of AISI1045 Based on Multiphase Model

Materials Science Forum ◽

10.4028/www.scientific.net/msf.836-837.374 ◽

2016 ◽

Vol 836-837 ◽

pp. 374-380

Author(s):

Teng Yi Shang ◽

Li Jing Xie ◽

Xiao Lei Chen ◽

Yu Qin ◽

Tie Fu

Keyword(s):

Cutting Force ◽

Cutting Process ◽

Multiphase Model ◽

Tool Edge Radius ◽

Edge Radius ◽

Tool Edge ◽

Cutting Insert ◽

Multiphase Models ◽

Hot Rolled ◽

Meso Scale

In the meso-scale machining, feed rate, grain size and tool edge radius are in the same order of magnitude, and cutting process is often carried out in the grain interior and grain boundary. In this paper the meso-cutting process of hot-rolled AISI1045 steel is studied and its metallographic microstructure is analyzed for the establishment of multiphase models which incorporate the effect of ferrite and pearlite grains. In order to discover the applicability of multiphase models to the simulation of meso-cutting, three contrast simulation models including multiphase model with rounded-edge cutting insert (model I), multiphase model with sharp edge cutting insert (model II) and equivalent homogeneous material model with rounded-edge cutting insert (model III) are built up for the meso-orthogonal cutting processes of hot-rolled AISI1045. By comparison with the experiments in terms of chip morphology, cutting force and specific cutting force, the most suitable model is identified. Then the stress distiribution is analyzed. And it is found that multiphase model with tool edge radius can give a more accurate prediction of the global variables and reveal more about these important local variables distribution.

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