An Approach to Improve Cutting Performance in Micromilling of Titanium Alloy

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
Yunn-Shiuan Liao ◽  
Tsung-Hsien Li ◽  
Yi-Chen Liu
Keyword(s):  
Carbon Dioxide ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Liquid Carbon ◽  
Dry Cutting ◽  
Machined Surface ◽  
Liquid Carbon Dioxide

Abstract Application of liquid carbon dioxide to improve cutting performance in micro-end milling of Ti-6Al-4V titanium alloy was proposed in this study. It was found that the machined roughness decreased with the cutting speed as observed in the conventional cutting, when a 0.5 mm diameter end milling cutter was used in dry cutting. But, the tiny and shattered chips produced by the use of 0.3 mm diameter cutter could adhere on the machined surface and deteriorate surface finish, if the cutting speed was higher than 40 m/min. Cutting temperature was effectively decreased by applying liquid carbon dioxide during micromilling, which in turn reduced the amount of chips adhering on the machined surface and lowered flank wear. The surface roughness Ra at a cutting speed of 70 m/min was improved from 0.09 μm under dry cutting to 0.04 μm under the liquid carbon dioxide assisted cutting condition. And there were no flank wear and very few burrs left on the machined surface for the condition used in the experiment. The height of the burrs was only 25% of that under dry cutting. More, minimum quantity lubrication (MQL) was proposed to be applied together with the liquid carbon dioxide to enhance lubrication effect. It was noted that the machined surface roughness was further decreased by 15% as compared with that when the liquid carbon dioxide was applied alone. The height of burrs was reduced from 32 μm to 16 μm.

An Analysis on Temperature & Surface Roughness during End Milling of Ti-6Al-4V Alloy

2014 ◽  
Vol 592-594 ◽  
pp. 38-42 ◽  
Author(s):  
S. Samsudeensadham ◽  
Vijayan Krishnaraj
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Metal Cutting ◽  
End Milling ◽  
Cutting Speed ◽  
Critical Issue ◽  
Vital Role ◽  
Effect Of Temperature ◽  
Regression Equations ◽  
Machined Surface

The heat produced in metal cutting process is one of the most critical issue in machining of titanium alloys. High temperature in metal cutting degrades the tool life, surface integrity, size accuracy and machining efficiency dramatically. The temperature generated during end milling of titanium alloy, has been measured using Thermo camera. Surface roughness plays a vital role in evaluating and measuring the quality of the machined surface. During the experiments, cutting speed and feed rate have been changed to analyse the effect of temperature and surface roughness. It is observed that cutting speed has the greater effect on temperature and surface roughness during end milling of titanium alloy. The regression equations generated have better fit which can be used for optimization.

scholarly journals Experimental Study on Surface Roughness and Flank Wear in Turning of Nimonic C263 under Dry Cutting Conditions

2021 ◽  
Vol 2021 ◽  
pp. 1-11
Author(s):  
J. Francis Xavier ◽  
B. Ravi ◽  
D. Jayabalakrishnan ◽  
Chakaravarthy Ezilarasan ◽  
V. Jayaseelan ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Controlling Factors ◽  
Average Error ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Machined Surface

Aircraft component manufacturing sector is looking for high precision machining in aircraft components. The present work explores the operability of green manufacturing of Nimonic C263 using dry turning. Nimonic C263 is tough to turn owing to its inherent quality like low conductivity and more work hardening. Therefore, in order to improve this machined surface/integrity, the controlling factors were optimized based on desirability approach for minimum of surface roughness and flank wear during turning of this alloy using CBN insert. L27 orthogonal array was chosen to carry out the experiment. The effects of controlling factors, such as cutting speed ( V ), feed rate ( S ), and cut penetration/depth of cut ( a p ) on the outputs, were also explored. The feed rate was a major impact to affect surface finish and flank wear. The average error percentage between the experimental and RSM models for surface finish was 4.76 percent and 2.79 percent for flank wear.

scholarly journals Influence of Chatter of VMC Arising During End Milling Operation and Cutting Conditions on Quality of Machined Surface

1970 ◽  
Vol 2 (1) ◽  
Author(s):  
A.K.M.N. Amin, M.A. Rizal, and M. Razman
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Metal Removal ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
End Mill ◽  
Machined Surface ◽  
Operating Cycle ◽  
Wide Range

Machine tool chatter is a dynamic instability of the cutting process. Chatter results in poor part surface finish, damaged cutting tool, and an irritating and unacceptable noise. Exten¬sive research has been undertaken to study the mechanisms of chatter formation. Efforts have been also made to prevent the occurrence of chatter vibration. Even though some progress have been made, fundamental studies on the mechanics of metal cutting are necessary to achieve chatter free operation of CNC machine tools to maintain their smooth operating cycle. The same is also true for Vertical Machining Centres (VMC), which operate at high cutting speeds and are capable of offering high metal removal rates. The present work deals with the effect of work materials, cutting conditions and diameter of end mill cutters on the frequency-amplitude characteristics of chatter and on machined surface roughness. Vibration data were recorded using an experimental rig consisting of KISTLER 3-component dynamometer model 9257B, amplifier, scope meters and a PC.  Three different types of vibrations were observed. The first type was a low frequency vibration, associated with the interrupted nature of end mill operation. The second type of vibration was associated with the instability of the chip formation process and the third type was due to chatter. The frequency of the last type remained practically unchanged over a wide range of cutting speed.  It was further observed that chip-tool contact processes had considerable effect on the roughness of the machined surface.Key Words: Chatter, Cutting Conditions, Stable Cutting, Surface Roughness.

Experimental Research of Effective Cutting Speed Influence on Surface Roughness in Ball End Milling of C45 Material with Hardness 34 HRC

2014 ◽  
Vol 657 ◽  
pp. 53-57 ◽  
Author(s):  
Sándor Ravai Nagy ◽  
Ioan Paşca ◽  
Mircea Lobonțiu ◽  
Mihai Banica
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Experimental Research ◽  
Inclination Angle ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Speed ◽  
Cnc Machine Tools ◽  
Machined Surface ◽  
Ball End Milling

Machining of Complex Concave or Convex Surfaces Requires the Use of Ball End Milling Cutters. Obtaining the Expected Surface Quality Compete Various Technological Factors which should be Taken into Account. Following the Machining of the Surface with Different Inclination Angles between the Cutting Tool Axes and the Machined Surface, Significant Changes of the Surface Roughness have been Observed. Based on the Tests Performed, we can Determine the Range of the Tool Inclination Angle, which is the Best for the Surface Quality. we have also Made a Correlation between the Cutting Speeds, Inclination Angle of the Cutting Tool Toward the Machined Surface for an Obtained Surface Quality. the Presented Results are Based on Experimental Research in Industrial Conditions by Using CNC Machine Tools with 5 Axes. the Tests have been Performed on the C45 Material, Heat Treated to 34HRC.

scholarly journals Analysis and Optimization of Cutting Tool Coating Effects on Surface Roughness and Cutting Forces on Turning of AA 6061 Alloy

2021 ◽  
Vol 2021 ◽  
pp. 1-12
Author(s):  
Mahir Akgün ◽  
Fuat Kara
Keyword(s):  
Surface Roughness ◽  
Mathematical Models ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Machined Surface ◽  
Tool Coating ◽  
Cutting Inserts

The present work has been focused on cutting force (Fc) and analysis of machined surface in turning of AA 6061 alloy with uncoated and PVD-TiB2 coated cutting inserts. Turning tests have been conducted on a CNC turning under dry cutting conditions based on Taguchi L18 (21 × 33) array. Kistler 9257A type dynamometer and equipment have been used in measuring the main cutting force (Fc) in turning experiments. Analysis of variance (ANOVA) has been applied to define the effect levels of the turning parameters on Fc and Ra. Moreover, the mathematical models for Fc and Ra have been developed via linear and quadratic regression models. The results indicated that the best performance in terms of Fc and Ra was obtained at an uncoated insert, cutting speed of 350 m/min, feed rate of 0.1 mm/rev, and depth of cut of 1 mm. Moreover, the feed rate is the most influential parameter on Ra and Fc, with 64.28% and 54.9%, respectively. The developed mathematical models for cutting force (Fc) and surface roughness (Ra) present reliable results with coefficients of determination (R2) of 96.04% and 92.15%, respectively.

Wear Performance of The Zirconia Toughened Alumina Added With TiO2 and Cr2O3 Ceramic Cutting Tool

2021 ◽  
Author(s):  
Raqibah Najwa Mudzaffar ◽  
Mohamad Faiz Izzat Bahauddin ◽  
Hanisah Manshor ◽  
Ahmad Zahirani Ahmad Azhar ◽  
Nik Akmar Rejab ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Crater Wear ◽  
Machined Surface ◽  
Ceramic Cutting Tool ◽  
Zirconia Toughened Alumina

Abstract The zirconia toughened alumina enhanced with titania and chromia (ZTA-TiO2-Cr2O3) ceramic cutting tool is a new cutting tool that possesses good hardness and fracture toughness. However, the performance of the ZTA-TiO2-Cr2O3 cutting tool continues to remain unknown and therefore requires further study. In this research, the wearing of the ZTA-TiO2-Cr2O3 cutting tool and the surface roughness of the machined surface of stainless steel 316L was investigated. The experiments were conducted where the cutting speeds range between 314 to 455 m/min, a feed rate from 0.1 to 0.15 mm/rev, and a depth of cut of 0.2 mm. A CNC lathe machine was utilised to conduct the turning operation for the experiment. Additionally, analysis of the flank wear and crater wear was undertaken using an optical microscope, while the chipping area was observed via scanning electron microscopy (SEM). The surface roughness of the machined surface was measured via portable surface roughness. The lowest value of flank wear, crater wear and surface roughness obtained are 0.044 mm, 0.45 mm2, and 0.50 µm, respectively at the highest cutting speed of 455 m/min and the highest feed rate of 0.15 mm/rev. The chipping area became smaller with the increase of feed rate from 0.10 to 0.15 mm/rev and larger when the feed rate decrease. This was due to the reduced vibrations at the higher spindle speed resulting in a more stable cutting operation, thereby reducing the value of tool wear, surface roughness, and the chipping area.

Surface Integrity and Fatigue Property of a High Speed Milled Titanium Alloy

2008 ◽  
Vol 53-54 ◽  
pp. 305-310 ◽  
Author(s):  
Guo Sheng Geng ◽  
Jiu Hua Xu
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Work Hardening ◽  
High Speed ◽  
Cutting Speed ◽  
Fatigue Property ◽  
Machined Surface ◽  
Metallurgical Structure

Surface integrity has a great effect on the fatigue property of titanium alloy. The surface integrity and fatigue property of a high speed milled Ti-6.5Al-2Zr-1Mo-1V (TA15) titanium alloy were investigated in this research. The main objective of this paper is to study the influence of milling speed on the surface integraty and fatigue property of the machined part. The surface roughness, work hardening, metallurgical structure and residual stress of the machined surface were studied in a cutting speed range of from 50m/min to 300m/min. To verify the relationship between cutting speed and the surface integrity of machined surface, the fatigue property of titanium alloy specimens milled at four different cutting speeds ranging from 50 to 200m/min were compared at two stress levels. This research shows that the cutting speed has little effect on the work hardening, metallurgical structure and residual stress, but the surface roughness decreases with the increasing cutting speed. Therefore, increasing milling speed has a positive effect on the surface integrity and fatigue property of the machined surface.

The Investigation of Prediction Surface Roughness from Machining Forces in End Milling Processes

2011 ◽  
Vol 486 ◽  
pp. 91-94 ◽  
Author(s):  
Jabbar Abbas ◽  
Amin Al-Habaibeh ◽  
Dai Zhong Su
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Irregular Waves ◽  
Depth Of Cut ◽  
End Mill ◽  
Machined Surface ◽  
Machining Forces ◽  
Mill Cutter

Surface roughness is one of the most significant parameters to determine quality of machined parts. Surface roughness is defined as a group of irregular waves in the surface, measured in micrometers (μm). Many investigations have been performed to verify the relationship between surface roughness and cutting parameters such as cutting speed, feed rate and depth of cut. To predict the surface produced by end milling, surface roughness models have been developed in this paper using the machining forces by assuming the end mill cutter as a cantilever beam rigidly or semi- rigidly supported by tool holder. An Aluminium workpiece and solid carbide end mill tools are used in this work. Model to predict surface roughness has been developed. Close relationship between machined surface roughness and roughness predicted using the measured forces signals.

The Effect of Cooling Lubrication Methods on Surface Roughness Measured by the White Light Interferometer

2009 ◽  
Vol 76-78 ◽  
pp. 471-478 ◽  
Author(s):  
Feng Jiang ◽  
Jian Feng Li ◽  
Jie Sun ◽  
Song Zhang
Keyword(s):  
Surface Roughness ◽  
White Light ◽  
End Milling ◽  
Cutting Parameters ◽  
Dry Cutting ◽  
Machined Surface ◽  
White Light Interferometer ◽  
3D Profile ◽  
Optimization Of Cutting Parameters ◽  
Lubrication Conditions

Surface roughness is an important item to evaluate the surface quality. Many researches focused on the optimization of cutting parameters in the specified cooling/lubrication conditions. But the effect of different cooling/lubrication conditions was still less considered. Aimed at this problem, the effect of cutting parameters on the average surface roughness (Ra) in the different cooling/lubrication conditions, including MQL, wet, dry cutting, was analyzed in this study. Orthogonal arrays were applied in the design of the experiments and Ti6Al4V end-milling experiments were performed on the DAEWOO machining center. The white light interferometer was used to obtain the 3D profile of machined surface and calculate the Ra values. The regression analysis and statistical analysis of variance were employed in the process of the experimental data. The relationships between Ra and cutting parameters in the different cooling/lubrication conditions were obtained and the optimum values of the cutting parameters in the range of the experiments were selected.

Optimization of Surface Roughness in End Milling of Titanium Alloy Ti-6Al-4V under the Influence of Magnetic Field from Permanents Magnets

2012 ◽  
Vol 576 ◽  
pp. 51-55 ◽  
Author(s):  
Syidatul Akma Sulaiman ◽  
A.K.M. Nurul Amin ◽  
M.D. Arif
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Permanent Magnets ◽  
End Milling ◽  
Desirability Function ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Central Composite

This paper presents the effect of cutting parameters on surface roughness in end milling of Titanium alloy Ti-6Al-4V under the influence of magnetic field from permanent magnets. Response Surface Methodology (RSM) with a small central composite design was used in developing the relationship between cutting speed, feed, and depth of cut, with surface roughness. In this experiment, three factors and five levels of central composite with 0.16817 alpha value was used as an approach to predict the surface roughness, in end milling of titanium alloy, with reasonable accuracy. The Design-Expert 6.0 software was applied to develop the surface roughness equation for the predictive model. The adequacy of the surface roughness model was validated to 95% by using ANOVA analysis. Finally, desirability function approach was used to determine the optimum possible surface roughness given the capabilities of the end machine.

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