scholarly journals A New Surface Topography-Based Method to Quantify Axial Error of High Speed Milling Cutters

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Wanqun Chen ◽  
Lei Lu ◽  
Wenkun Xie ◽  
Dehong Huo ◽  
Kai Yang
Keyword(s):  
Surface Topography ◽  
High Speed ◽  
Cutting Tool ◽  
Axial Direction ◽  
Machined Surface ◽  
High Rotational Speed ◽  
High Speed Milling ◽  
Tool Marks ◽  
Machined Surface Quality ◽  
Novel Method

Cutting tool rotation errors have significant influence on the machined surface quality, especially in micromilling. Precision metrology instruments are usually needed to measure the rotation error accurately. However, it is difficult to directly measure the axial error of micromilling tools due to the small diameters and ultra-high rotational speed. To predict the axial error of high speed milling tools in the actual machining conditions and avoid the use of expensive metrology instruments, a novel method is proposed in this paper to quantify the cutting tool error in the axial direction based on the tool marks generated on the machined surface. A numerical model is established to simulate the surface topography generation, and the relationship between tool marks and the cutting tool axial error is then investigated. The tool axial errors at different rotational speeds can be detected by the proposed method. The accuracy and the reliability of the proposed method are verified by machining experiments.

Analysis of Surface Morphology in Work Hardening of High-Speed Milling Based on Dislocation Theory

2013 ◽  
Vol 373-375 ◽  
pp. 2015-2018
Author(s):  
Wen Jie Yang ◽  
Su Yu Wang ◽  
Yuan Chao Du ◽  
Lin Lin Ma
Keyword(s):  
Surface Quality ◽  
Work Hardening ◽  
High Speed ◽  
Lattice Distortion ◽  
Dislocation Theory ◽  
Machined Surface ◽  
High Speed Milling ◽  
Forming Mechanism ◽  
Machined Surface Quality ◽  
Micro Morphology

Work hardening is an important index for the evaluation of the machined surface quality in high-speed milling. The morphology of work hardening can be visually observed by the metallographic pictures of high-speed milling gained from the scanning electron microscope which includes the lattice distortion and cracks etc. Forming mechanism of lattice distortion and micro crack of micro morphology under the workpiece surface is analyzed according to the dislocation theory; meanwhile, the effects on surface quality of the microstructure of the work hardening layer are discussed, which have important guiding significances on improving the surface quality and prolonging the service life of the parts.

Advances in High-Speed Milling of Metal Matrix Composites

2012 ◽  
Vol 499 ◽  
pp. 9-14
Author(s):  
Ying Fei Ge ◽  
Jiu Hua Xu ◽  
Y.C. Fu ◽  
S. Zhang ◽  
W.L. Bian
Keyword(s):  
Metal Matrix Composites ◽  
Surface Quality ◽  
Tool Life ◽  
Metal Matrix ◽  
High Speed ◽  
Cutting Parameters ◽  
Matrix Composites ◽  
Machined Surface ◽  
High Speed Milling ◽  
Machined Surface Quality

Particle reinforced metal matrix composites (PMMC) possess many outstanding properties and are increasingly applied in automobile, aerospace, electronics and medical industries. However, PMMC is a typical difficult-to-machining material due to the rapid tool wear rate and excessive machining induced defects. Although large amount of investigations have been done on the conventional machining of PMMC, merely several researchers have dedicated themselves to the study of milling, especially high speed milling of this material. Within the milling studies, most researchers have selected the carbide coated or uncoated solid carbide tools whose tool life was not satisfactory for engineering application. The literatures review indicates that most researchers limited their study to sintering or casting SiCp/Al composites at the low or moderate cutting speed. Material produced by the in-situ reaction method or titanium matrix composites was seldom selected as the research object. The research content was limited to the effect of cutting parameters on the machined surface quality or cutting forces. It is suggested that high-speed milling with PCD tool should be conducted in order to improve the machined surface quality and material removal rate and decrease the machining cost. Tool life modeling, surface roughness prediction, cutting parameters optimization and high-speed milling data base and the expert system should be greatly noticed by the researchers.

Study on Surface Roughness in High-Speed Milling for ALMn1Cu

2012 ◽  
Vol 157-158 ◽  
pp. 636-640 ◽  
Author(s):  
Zhen Hua Wang ◽  
Jun Tang Yuan ◽  
Jun Huang
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Analysis Of Variance ◽  
High Speed ◽  
Cutting Parameters ◽  
Factorial Experiments ◽  
Machined Surface ◽  
High Speed Milling ◽  
Machined Surface Quality ◽  
Cutting Experiments

Anti-rust aluminum is widely used in aviation, aerospace, communications, as well as weapons with non-corrosion, light, and other fine characteristic. In this study, in order to improve the machined surface quality and reduce the surface roughness and find the influence of the cutting parameters on the surface roughness, a series of cutting experiments for AlMn1Cu are conducted to obtain surface roughness values in high-speed milling. According to the analysis of variance (ANOVA) of factorial experiments, the cutting parameters significantly influencing on the surface roughness were presented.

scholarly journals Analysis Method for Surface Topography Model in High Speed Milling Hardened Steel

2015 ◽  
Vol 9 (1) ◽  
pp. 219-225 ◽  
Author(s):  
Jiang Bin ◽  
Zhang Minghui ◽  
Wang Zhigang ◽  
Guan Yancong
Keyword(s):  
Surface Topography ◽  
High Speed ◽  
End Milling ◽  
Hardened Steel ◽  
Formation Condition ◽  
Machined Surface ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Contact Points ◽  
Milled Surface

During high speed milling hardened steel, the problem that tool vibration reducing machining surface quality causes led to a research for the influence characteristics of milled surface topography through high speed milling experiment. To determine the formation condition of milled surface topography, using displacement increment of origin of tool coordinate system which is caused by the milling cutter vibration and installation error, modifies the cutting motion trajectory. Based on the tool-workpiece contact relationship and the cutting layer parameters of contact points on two teeth, the residual units of machined surface are established, thereby proposing a solution method for the deformation and distribution characteristic of residual units under the overhanging volume and the vibration. Therefore, the milled surface topography of cutting hardness steel with high speed ball-end milling cutter is revealed to bring out a striking contrast between the simulation and experiment of milled surface topography of hardness steel.

Discrete Element Simulation of the Stress Wave in High Speed Milling

2017 ◽  
Author(s):  
Yifei Jiang ◽  
Jun Zhang ◽  
Yong He ◽  
Hongguang Liu ◽  
Afaque Rafique Memon ◽  
...  
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Discrete Element ◽  
Rake Angle ◽  
Stress Waves ◽  
High Speed Milling ◽  
Element Simulation ◽  
Chip Size ◽  
Distribution Of Stress

As cutting tool penetrates into workpiece, stress waves is induced and propagates in the workpiece. This paper aims to propose a two-dimensional discrete element method to analyze the stress waves effects during high speed milling. The dependence of the stress waves propagation characteristics on rake angle and cutting speed was studied. The simulation results show that the energy distribution of stress waves is more concentrated near the tool tip as the rake angle or the cutting speed increases. In addition, the density of initial cracks in the workpiece near the cutting tool increases when the cutting speed is higher. The high speed milling experiments indicate that the chip size decreases as the cutting speed increases, which is just qualitatively consistent with the simulation.

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

Optical Effects of Surface Finish by Ultraprecision Single Point Diamond Machining

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
Lei Li ◽  
Stuart A. Collins ◽  
Allen Y. Yi
Keyword(s):  
Surface Quality ◽  
Single Point ◽  
Diamond Turning ◽  
Optical Diffraction ◽  
Machining Process ◽  
Machined Surface ◽  
Tool Marks ◽  
Tool Mark ◽  
Machined Surface Quality ◽  
Machined Surfaces

The single point diamond turning process has been used extensively for direct optical surface fabrication. However, the diamond machined surfaces have characteristic periodic tool marks, which contribute to reduced optical performance such as scattering and distortion. In this paper, studies of the characteristics of diamond machined surface and scattering from the diamond machined surfaces are presented. Four different parameters, the first order optical diffraction, the zero order reflection, the surface roughness, and the residual tool mark depth, are used as indicators for the machined surface quality. Four sets of tests are presented showing the relationship between machined surface quality and machining conditions such as spindle speed, feedrate, and machining process. Finally, an empirical model is given based on the measurements.

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