Milling Burr Size Estimation Using Acoustic Emission and Cutting Forces

2011 ◽  
Author(s):  
Seyed Ali Niknam ◽  
Azziz Tiabi ◽  
Imed Zaghbani ◽  
Rene Kamguem ◽  
Victor Songmene
Keyword(s):  
Acoustic Emission ◽  
Cutting Forces ◽  
Estimation Method ◽  
Cutting Speed ◽  
Measurement Methods ◽  
Estimation Methods ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Size Estimation ◽  
Burr Size

Burr formation is one of the main concerns usually faced by machining industries. Its presence leads to additional part edge finishing operations that are costly and time consuming. Burrs must be removed as they are source of dimensional errors, jamming and misalignment during assembly. In many cases burrs may injure workers during handling of machined part. Due to burr effect on machined part quality, manufacturing costs and productivity, more focus has been given to burr measurement/estimation methods. Large number of burr measurement methods has been introduced according to various criteria. The selection of appropriate burr size estimation method depends on number of factors such as desired level of quality and requested measuring accuracy. Traditional burr measurement methods are very time consuming and costly. This article aims to present empirical models using acoustic emission (AE) and cutting forces signals to predict entrance and exit burrs size in slot milling operation. These models can help estimating the burrs size without having to measure them. The machining tests were carried on Al 7075-T6 aluminum alloy using 3 levels of cutting speed, 3 levels of feed rate, 3 levels of cutting tool coating and 2 levels of depth of cut. Mathematical models were developed based on most sensitive AE parameters following statistical analysis, cutting forces and their interaction on predicting the entrance and exit burrs size. The proposed models correlate very well with the measured burrs size data.

Burr formation and correlation with cutting force and acoustic emission signals

2016 ◽  
Vol 231 (3) ◽  
pp. 399-414 ◽  
Author(s):  
Seyed Ali Niknam ◽  
Victor Songmene
Keyword(s):  
Acoustic Emission ◽  
Cutting Force ◽  
Formation Mechanism ◽  
Acoustic Emission Signal ◽  
Cutting Forces ◽  
Burr Formation ◽  
Slot Milling ◽  
Emission Signal ◽  
Burr Size ◽  
Milling Operation

The principle objective of this work is to present a methodology to evaluate the correlation between burr size attributes (thickness and height) and information computed from acoustic emission and cutting forces signals. In the proposed methodology, cutting force and acoustic emission signals were recorded in each cutting test, and each recorded original acoustic emission signal was segmented into two sections that correspond to steady-state cutting process (cutting signal) and cutting tool exit from the work part (exit signal). The dominant acoustic emission signal parameters including AEmax and AErms were computed from each segmented acoustic emission signal. The maximum values of directional cutting forces (FX, FY and FZ) were also measured in each trial. The experimental verification was conducted on slot milling operation which has relatively more complicated burr formation mechanism than that in many other traditional machining operations. Among slot milling burrs, the top-up milling side burrs and exit burrs along up milling side were largest and thickest burrs which were studied in this work. To evaluate the correlation between signal information and burr size, the computed signal information (5 parameters) and their interaction effects (10 parameters) were used to construct the input parameters of the multiple regression fitted models. Statistical methods were then used to assess the adequacy of individual input parameters and signal information. Using the acoustic emission and cutting force signals information in the input layer of multiple regression models, a high correlation was observed between the predicted and observed values of burr size. It was exhibited that due to complex burr formation mechanism in milling operation and strong interaction effects between cutting process parameters, no systematic relationship can be formulated between the milling burrs.

Micro-Milling of Hardened AISI D2 Tool Steel

2012 ◽  
Vol 445 ◽  
pp. 62-67 ◽  
Author(s):  
J.B. Saedon ◽  
S.L. Soo ◽  
D.K. Aspinwall ◽  
A. Barnacle
Keyword(s):  
Tool Wear ◽  
Tool Steel ◽  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Operating Conditions ◽  
Micro Milling ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Aisi D2

The paper presents an experimental investigation into the slotting of hardened AISI D2 (~62HRC) tool steel using 0.5mm diameter coated (TiAlN) tungsten carbide (WC) end mills. SEM analysis of tool morphology and coating integrity was undertaken on all tools prior to testing. Tool wear details are given based on resulting cutter diameter and slot width reduction. In addition, cutting forces are also presented together with details of workpiece burr formation. A full factorial experimental design was used with variation of cutting speed, feed rate and depth of cut, with results evaluated using analysis of variance (ANOVA) techniques. Parameter levels were chosen based on microscale milling best practice and results from preliminary testing. Main effects plots and percentage contribution ratios (PCR) are included for the main factors. Cutting speed was shown to have the greatest effect on tool wear (33% PCR). When operating at 50m/min cutting speed with a feed rate of 8µm/rev and a depth of cut of 55µm, cutter diameter showed a reduction of up to 82µm for a 520mm cut length. SEM micrographs of tool wear highlighted chipping / fracture as the primary wear mode with adhered workpiece material causing further attritious wear when machining was continued up to 2.6m cut length. All tests produced burrs on the top edges of the slots which varied in size / width to a lesser or greater degree. Under the most severe operating conditions, burr width varied from approximately 50µm to more than 220µm over the 520mm cut length. Cutting forces in general were less than 12N up to test cessation.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Predictive Modeling and Optimization of Cutting Forces Through RSM and Taguchi Techniques in the Turning of ASTM B574 (Hastelloy C-22)

2018 ◽  
pp. 398-417
Author(s):  
İsmail Kırbaş ◽  
Musa Peker ◽  
Gültekin Basmacı ◽  
Mustafa Ay
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Orthogonal Experimental Design ◽  
Depth Of Cut ◽  
Effective Parameters ◽  
Factors Affecting ◽  
The Impact

In this chapter, the impact of cutting parameters (depth of cut, cutting speed, feed, flow, rake angle, lead angle) on cutting forces in the turning process with regard to ASTM B574 (Hastelloy C-22) material has been investigated. Variance analysis has been applied in order to determine the factors affecting the cutting forces. The optimization of the parameters affecting the surface roughness has been obtained using response surface methodology (RSM) based on the Taguchi orthogonal experimental design. The accuracy of the developed models required for the estimation of the force values (Fx, Fy, Fz) is quite successful. In this study, where the R2 value has been used as the criterion/measure, accuracy values of 93.35%, 95.03%, and 95.09% have been achieved for Fx, Fy, and Fz, respectively. As a result of the ANOVA analysis, the most effective parameters for Fx at a 95% confidence interval are depth of cut, feed rate, flow, and rake angle. The most effective parameter for Fy is depth of cut, while the most effective parameters for Fz are depth of cut, feed rate, and flow, respectively.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

The machinability of Al/B4C composites produced by hot pressing based on reinforcing the element ratio

2016 ◽  
Vol 23 (6) ◽  
pp. 743-750 ◽  
Author(s):  
Ergün Ekici ◽  
Mahmut Gülesin
Keyword(s):  
Surface Roughness ◽  
Wear Mechanism ◽  
Cutting Forces ◽  
Hot Pressing ◽  
Matrix Material ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Reinforcement Ratio ◽  
Depth Of Cut ◽  
Crater Wear

AbstractIn this study, the effects of the particle reinforcement ratio on cutting forces and surface roughness were investigated when milling particle-reinforced metal matrix composite (MMCp) produced by hot pressing with different cutting tools. Alumix 123 alloy as the matrix material and B4C particles with an average size of 27 μm and 5%, 10% and 15% ratio as reinforcing elements were used for the manufacture of composite materials. The experiments were carried out in dry cutting conditions with four different cutting speeds, constant feed rate and depth of cut. Changes depending on the increased reinforcement ratio in cutting forces and surface roughness values were investigated; the effects of 10% B4C reinforced composite on tool wear were also examined. It was observed that cutting forces increased with the increase in cutting speed and particle ratio with carbide cutting tools, and it was seen that the cutting forces on the cutting tools decreased when cutting speed decreased and the cutting forces increased as the reinforcement ratios increased. In addition, with increasing the cutting speed, the surface roughness of the machined surfaces of composite samples increased with the carbide tools, while the cubic boron nitride (CBN) tools have the opposite effect. While it was seen that flank and crater wear occurred on the cemented carbide cutting tools, abrasive, adhesive and other wear mechanism tools in addition to the main wear mechanism, no remarkable flank and crater wear occurred on CBN cutting tools.

Investigation of Ultrasonic-Assisted Drilling of Al/SiC Metal Matrix Composite with Taguchi Method

2012 ◽  
Vol 523-524 ◽  
pp. 215-219 ◽  
Author(s):  
Mohammad Ali Kadivar ◽  
Javad Akbari ◽  
Reza Yousefi
Keyword(s):  
Taguchi Method ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Burr Formation ◽  
Burr Height ◽  
Burr Size ◽  
Ultrasonic Assisted ◽  
Drilling Parameter ◽  
Sic Particle

Burr in drilling plays an important role on product quality, so analysis the burr size is essential at the final production. This paper presents the application of Taguchi method for survey the burr height and burr thickness by adding ultrasonic vibration to the process. In this paper L18 orthogonal array based on Taguchi techniques was used in the design of experiments. Analysis of Variance (ANOVA) was used to determination the effect of drilling parameter on burr formation. Influence of cutting speed, feed rate and percentage of SiC particle was investigated in with and without Ultrasonic assisted drilling. Al/SiCp MMC with 5, 15 and 20 wt% of particulate SiC in dry drilling operation with TiN coated drill tools were investigated.

Assessment of the Cutting Tooling Effect on Turning Chatter

2013 ◽  
Vol 433-435 ◽  
pp. 2101-2106
Author(s):  
Joon Hwang ◽  
Ey Hyoun Jeong ◽  
Eui Sik Chung ◽  
Steven Y. Liang
Keyword(s):  
Cutting Forces ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Nonlinear Phenomenon ◽  
Chatter Vibration ◽  
Machining Performance ◽  
Dynamic Component ◽  
Excited Vibration ◽  
Overhang Length

Machining performance is often limited by chatter vibration at the tool-workpiece interface. Chatter is a type of machining self-excited vibration which originates from the variation in cutting forces and the flexibility of the machine tool structure. Machining chatter is an inherently nonlinear phenomenon that is affected by many parameters such as cutting conditions, tool geometry, cutting speed, feed rate, depth of cut, overhang length of tool, clamping condition of workpiece. This study presents experimental approach for investigation of effects of various cutting tool geometry on the onset of chatter. In turning process, measured cutting force signal and triaxial accelerometer signal was used to know the characteristics of chatter vibration. The static and dynamic component of cutting forces reflect onset of chatter vibration. Proper selection of tooling is an important parameter in terms of chatter elimination in machining.

Burr Size Minimization When Drilling 6061-T6 Aluminum Alloy

2012 ◽  
Author(s):  
Y. Zedan ◽  
S. A. Niknam ◽  
A. Djebara ◽  
V. Songmene
Keyword(s):  
Process Parameters ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Cutting Fluid ◽  
Burr Formation ◽  
Formation Mechanisms ◽  
Regression Equations ◽  
Taguchi Optimization ◽  
Burr Height ◽  
Burr Size

The burr formation mechanisms strongly depend on the machining methods as well as cutting conditions. Cutting fluids play significant roles in machining, including reduction of friction and temperature. Using a cutting fluid, however, degrades the quality of the environment and increases machining costs. In the present work, initially the effects of cutting fluid application (dry, mist and flood) and their interaction with cutting parameters on the burr size during drilling of 6061-T6 aluminum alloys were investigated using multi-level full factorial design. Second-order non-linear mathematical models were developed to predict burr height for various lubrication modes. The accuracy of the regression equations formulated to predict burr height when using different lubrication modes has been verified through carrying out random experiments in the range of variation of these variables. A procedure was developed to minimize burr size for drilling holes by presenting the optimal levels of process parameters. Taguchi optimization method based on L9 orthogonal array design of experiment was then used which has shown very accurate process parameters selection that leads to minimum burr height. According to experimental study, it was observed that dry and mist drilling can produce parts with quality comparable with those obtained in wet drilling when using the optimal cutting conditions. In addition, increase in cutting speed and feed rate exhibits a decrease in burr size.

Cutting Model in Machining of Al/SiCp Metal Matrix Composite

2011 ◽  
Vol 410 ◽  
pp. 291-297
Author(s):  
Sayed Mohamad Nikouei ◽  
R. Yousefi ◽  
Mohammad Ali Kouchakzadeh ◽  
M.A. Kadivar
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Shear Plane ◽  
Good Method ◽  
Depth Of Cut ◽  
Machining Forces ◽  
Experimental Cutting ◽  
Cutting Model

Prediction of shear plane angle is a way for prediction of the mechanism of chip formation, machining forces and so on. In this study, Merchant and Lee-Shaffer theories are used for prediction of shear plane angles and cutting forces in machining of Al/SiCpMMC with 20% of SiC as reinforcement particles. The experimental cutting forces are compared with the calculated cutting force based on shear plane angles extracted from Merchant and Lee-Shaffer theories. The variation of these cutting forces with cutting speed, feed rate and depth of cut has been discussed. The results showed that Merchant theory may be used as a good method for prediction of chip formation in machining of Al/SiCpMMC.

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