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

2014 ◽  
Vol 67 (3) ◽  
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.

Research on Machined Surface Quality of High Speed Hard Machining for Harden Steel

2012 ◽  
Vol 500 ◽  
pp. 82-88 ◽  
Author(s):  
Cai Xu Yue ◽  
Xian Li Liu ◽  
Da Wei Sun ◽  
Ming Yang Wu
Keyword(s):  
Surface Quality ◽  
High Speed ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Machining Process ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Machined Surface Quality ◽  
Side Flow

For its good processing flexible, economic and environmental protection performance, hardened steel GCr15 is used widely in car and energy industry. Although surface quality in machining process is not controlled well, that restricts application of hardened steel GCr15 extensive to a certain degree. Therefore, this study revealed the effect of cutting parameters on surface roughness. Also influence of cutting conditions on surface morphology and organization generation mechanism of subsurface were stuied for high-speed cutting hardened steel GCr15. Appear reasons of plastic side flow on surface was researched. Also, effect of tool wear on surface quality was studied as well. The research results provided theoretical basis for rational choice for high speed hardened steel cutting process.

Experimental Investigation on the Effect of Tool Geometry and Cutting Conditions Using Tool Wear Prediction Model for End Milling Process

2014 ◽  
Vol 13 (01) ◽  
pp. 41-54 ◽  
Author(s):  
S. Kalidass ◽  
P. Palanisamy
Keyword(s):  
Tool Wear ◽  
End Milling ◽  
Cutting Parameters ◽  
304 Stainless Steel ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cutting Condition ◽  
Machining Parameter

Tool wear of a cutting tool has a significant impact on the tool life and surface quality of the finished product. Tool wear is influenced by many factors such as cutting parameters, tool geometry, coating type, work piece material, chatter, and cutting condition. In the present work, the design of experiments (DOE) technique has been used for four factors at five levels to conduct experiments. Tool wear is taken as the response variable measured during end milling, while helix angle, spindle speed, feed and depth of cut are taken as the input parameters. The material and tool selected for this study are AISI 304 stainless steel and uncoated solid carbide end mill cutter respectively. The tool wear was measured using tool maker's microscope. The experimental values are used in six sigma software for finding the coefficients to develop the regression model. The direct and interaction effect of the machining parameter with tool wear were analyzed using contour graphs, which helped to select process parameters for reducing tool wear and also ensure quality of milling.

scholarly journals Deformation Structures and Tool Wear during High-Speed Machining

2013 ◽  
Vol 10 (1) ◽  
pp. 12-17
Author(s):  
Karol Vasilko
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Tool Material ◽  
Machining Process ◽  
Surface Dynamics ◽  
Machined Surface ◽  
Deformation Structures ◽  
Cutting Speeds ◽  
Tool Durability

Abstract Tendencies towards increasing cutting speeds during machining can be observed recently. The first wave of increasing cutting speeds occured in the 60s of the previous century. However, suitable tool material was not available at that time. Increasing cutting speed is possible only following the development of cutting material, resistant against high temperatures, abrasive, adhesive and diffusive wear. It is obvious that the process of chip creation, quality of machined surface, dynamics of machining process and temperature of cutting change considerably with cutting speed. To be able to apply higher cutting speeds in production machining, it is necessary to know the dependence of those characteristics on cutting speed. Some of those phenomena, which are linked with cutting speed, will be explained in the paper. Key words: machining, cutting speed, tool durability, surface quality

scholarly journals Analyzing the Effect of Machining Parameters Setting to the Surface Roughness during End Milling of CFRP-Aluminium Composite Laminates

2016 ◽  
Vol 2016 ◽  
pp. 1-9 ◽  
Author(s):  
M. Nurhaniza ◽  
M. K. A. M. Ariffin ◽  
F. Mustapha ◽  
B. T. H. T. Baharudin
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimal Cutting Parameters ◽  
Cnc End Milling

The quality of the machining is measured from surface finished and it is considered as the most important aspect in composite machining. An appropriate and optimum machining parameters setting is crucial during machining operation in order to enhance the surface quality. The objective of this research is to analyze the effect of machining parameters on the surface quality of CFRP-Aluminium in CNC end milling operation with PCD tool. The milling parameters evaluated are spindle speed, feed rate, and depth of cut. The L9 Taguchi orthogonal arrays, signal-to-noise (S/N) ratio, and analysis of variance (ANOVA) are employed to analyze the effect of these cutting parameters. The analysis of the results indicates that the optimal cutting parameters combination for good surface finish is high cutting speed, low feed rate, and low depth of cut.

Ensuring surface quality of parts in high-speed end milling of quenched steel

2008 ◽  
Vol 28 (12) ◽  
pp. 1248-1251
Author(s):  
I. E. Kiryushin ◽  
D. E. Kiryushin ◽  
T. G. Nasad
Keyword(s):  
Surface Quality ◽  
High Speed ◽  
End Milling ◽  
Quenched Steel

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

scholarly journals Research on Cutting Performance in High-speed Milling of TC11 Titanium Alloy Using Self-propelled Rotary Milling Cutters

2021 ◽  
Author(s):  
Yujiang Lu ◽  
Tao Chen
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Quality ◽  
Wear Mechanism ◽  
High Speed ◽  
Cutting Edge ◽  
Machining Process ◽  
High Speed Milling ◽  
Tc11 Titanium Alloy ◽  
Milling Forces

Abstract Titanium alloy materials, with excellent chemical and physical properties, are widely applied to the manufacture of key components in the aerospace industry. Nevertheless, its hard-to-machine characteristic causes various problems in the machining process, such as severe tool wear, difficulty to ensure good surface quality, etc. To achieve high efficiency and quality of machining titanium alloy materials, this paper conducted an experimental research on the high-speed milling of TC11 titanium alloy with self-propelled rotary milling cutters. In the work, the wear mechanism of self-propelled rotary milling cutters was explored, the influence of milling velocity was analyzed on the cutting process, and the variation laws were obtained of milling forces, chip morphology and machined surface quality with the milling length. The results showed that in the early and middle stages of milling, the insert coating peeled off evenly under the joint action of abrasive and adhesive wear mechanisms. As the milling length increased, the dense notches occurred on the cutting edge of the cutter, the wear mechanism converted gradually into fatigue wear, and furthermore coating started peeling off the cutting edge with the occurrence of thermal fatigue cracks on the insert. As the milling length was further extended, the milling forces tended to intensify, the chip deformation worsened, and the obvious cracks occurred at the bottom of chips. Moreover, the rise in milling velocity reduced the tool wear resistance, increased obviously the milling forces and the surface roughness.

Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ahsana Aqilah Ahmad ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanism ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Content Type ◽  
Radial Depth

Purpose The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid. Design/methodology/approach The experiments were designed using Taguchi L9 orthogonal array with the parameters chosen: cutting speed (between 300 and 400 m/min), feed rate (between 0.15 and 0.3 mm/tooth), axial depth of cut (between 0.5 and 0.7 mm) and radial depth of cut (between 0.3 and 0.7 mm). Toolmaker microscope, optical microscope and Hitachi SU3500 Variable Pressure Scanning Electron Microscope used to measure tool wear progression and wear mechanism. Findings Cutting speed 65.36%, radial depth of cut 24.06% and feed rate 6.28% are the cutting parameters that contribute the most to the rate of tool life. The study of the tool wear mechanism revealed that the oxide layer was observed during lower and high cutting speeds. The former provides a cushion of the protective layer while later reduce the surface hardness of the coated tool Originality/value A high-speed regime is usually carried out in dry conditions which can shorten the tool life and accelerate the tool wear. Thus, this research is important as it investigates how the use of MQL and cutting parameters can prolong the usage of tool life and at the same time to achieve a sustainable manufacturing process.

Comparative Study of Material Damage and Tool Wear Mechanisms During Drilling of CFRP/Ti Stack

2019 ◽  
Author(s):  
Vijayathithan Mathiyazhagan ◽  
Anil Meena
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
Cutting Parameters ◽  
Burr Formation ◽  
Mechanical And Thermal Properties ◽  
Hole Quality ◽  
Structural Functions ◽  
Tool Wear Mechanisms ◽  
Rapid Tool

Abstract The usage of CFRP and Ti stacks in the aerospace industry has widely increased due to its mechanical properties and improved structural functions but at the same time, different mechanical and thermal properties of the CFRP and Ti makes the process difficult. Major apprehensions in the drilling of CFRP/Ti stacks include rapid tool wear and poor hole quality. Typically, the surface quality of the holes in the drilling of CFRP/Ti stack is poor due to delamination, the progression of hole diameter in CFRP and burr formation in Ti. Moreover, the flank wear on the tool also influences the surface quality of the hole produced. Therefore, the present study is mainly focused on the influence of cutting parameters on cutting forces, hole quality and tool wear characteristics. Drilling was performed on CFRP/Ti stack using coated and uncoated carbide tools. The obtained results revealed a significant correlation between tool wear and delamination characteristics.

Acoustic Emission in Stainless Steel End Milling with Carbide Tools

2017 ◽  
Vol 753 ◽  
pp. 206-210
Author(s):  
Peter Babatunde Odedeyi ◽  
Khaled Abou-El-Hossein ◽  
Muhammad M. Liman ◽  
Abubakar I. Jumare ◽  
Abdulqadir N. Lukman
Keyword(s):  
Stainless Steel ◽  
Acoustic Emission ◽  
Tool Wear ◽  
Manufacturing Industry ◽  
End Milling ◽  
Cutting Parameters ◽  
Machining Process ◽  
Dimensional Precision ◽  
Tool Monitoring ◽  
Machined Parts

Tool wear is a complex phenomenon, it worsens surface quality, increases power consumption, and causes rejection of machined parts. Tool wear has a direct effect on the quality of the surface finish of the workpiece, dimensional precision and ultimately the cost of the parts produced. In modern automated manufacturing machines, tool monitoring system for automated machines should be capable of operating on-line and interpret the working condition of machining process at a given point in time. Therefore, there is a need to develop a continuous tool monitoring systems that would notify operator the state of tool in order to avoid tool failure or undesirable circumstances. This study therefore uses acoustic emission (AE) sensing techniques, signal processing and Artificial Neural Networks (ANN) frameworks to model and validate the machining process. The AE showed effects of tool breakage and ANN predictions closest to the experimental cutting parameters were obtained. It was also shown that the ANN prediction model obtained is a useful, reliable and quite effective tool for modeling tool wear of carbide tools when working on stainless steel. Thus, the results of the present research can be successfully applied in the manufacturing industry to reduce the time, energy and high experimental costs.

Sign in / Sign up

Export Citation Format

Share Document