Modeling the surface roughness in face-end milling process by using general insert at stable cutting conditions

2020 ◽  
Vol 34 (22n24) ◽  
pp. 2040143
Author(s):  
Le Hong Ky ◽  
Nhu-Tung Nguyen ◽  
Duc Trung Do ◽  
Tien Dung Hoang ◽  
Hoang Anh Le
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Calculation Model ◽  
Milling Process ◽  
Cutting Condition ◽  
End Mill ◽  
Nose Radius ◽  
Developed Surface ◽  
Milling Condition

Predicting the quality of the machined components is the grandiose signification in industrial manufacturing. Calculation of the surface roughness is one of the most important elements to predict the quality of machined parts. In this paper, the surface roughness was modeled in the face-end mill process by using general rhombu insert. In the proposed mathematical model, with the stable milling condition, the surface roughness is formulated by a function of feed rate, and insert geometry such as nose radius and nose angle. An experimental method is proposed based on the stable milling condition to estimate the surface roughness. The developed surface roughness calculation model has been successfully verified by both simulation and experiment with very promising results. The average difference between predicted and experimental results is 7.59%. The proposed model can be applied to predict the surface roughness in face-end mill processes by using general insert at stable cutting condition.

DECODING OF THE RELATION BETWEEN FRACTAL STRUCTURE OF CUTTING FORCE AND SURFACE ROUGHNESS OF MACHINED WORKPIECE IN END MILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (04) ◽  
pp. 1950054 ◽  
Author(s):  
HAMIDREZA NAMAZI ◽  
ALI AKHAVAN FARID ◽  
TECK SENG CHANG
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
End Milling ◽  
Complex Structure ◽  
Dry Machining ◽  
End Mill ◽  
Milling Operation ◽  
Machining Operations

Analysis of the surface quality of workpiece is one of the major works in machining operations. Variations of cutting force is an important factor that highly affects the quality of machined workpiece during operation. Therefore, investigating about the variations of cutting forces is very important in machining operation. In this paper, we employ fractal analysis in order to investigate the relation between complex structure of cutting force and surface roughness of machined surface in end milling operation. We run the machining operation in different conditions in which cutting depths, type of cutting tool (serrated versus square end mills) and machining conditions (wet and dry machining) change. Based on the obtained results, we observed the relation between complexity of cutting force and surface roughness of generated surface of machined workpiece due to engagement with the flute surface of end mill, in case of using square end mill in dry machining condition, and also in case of using serrated end mill in wet machining condition. The fractal approach that was employed in this research can be potentially examined in case of other machining operations in order to investigate the possible relation between complex structure of cutting force and surface quality of machined workpiece.

Surface Roughness Prediction in Ball-End Milling Process for Aluminum by Using Air Blow Cutting

2011 ◽  
Vol 418-420 ◽  
pp. 1428-1434 ◽  
Author(s):  
Keerati Karunasawat ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Tool Diameter ◽  
End Milling Process

The objective of this research is to develop the surface roughness and cutting force models by using the air blow cutting of the aluminum in the ball-end milling process. The air blow cutting proposed in order to reduce the use of the cutting fluid. The surface roughness and cuttting force models are proposed in the exponential forms which consist of the cutting speed, the feed rate, the depth of cut, the tool diameter, and the air blow pressure. The coefficients of the surface roughness and cutting force models are calculated by utilizing the multiple regression with the least squared method at 95% significant level. The effects of cutting parameters on the cutting force are investigated and measured to analyze the relation between the surface roughness and the cutting conditions. The experimentally obtained results showed that the cutting force has the same trend with the surface roughness. The surface plots are constructed to determine the optimum cutting condition referring to the minimum surface roughness.

Investigation of Dry Cutting and Applications of Cutting Fluid in Ball-End Milling Process

2011 ◽  
Vol 291-294 ◽  
pp. 3013-3023 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Channarong Rungruang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Parameters ◽  
Milling Process ◽  
Cutting Fluid ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Ball End Milling ◽  
End Milling Process

In order to realize the environmental hazard, this paper presents the investigation of the machinability of ball-end milling process with the dry cutting, the wet cutting, and the mist cutting for aluminum. The relations of the surface roughness, the cutting force, and the cutting parameters are examined based on the experimental results by using the Response Surface Analysis with the Box-Behnken design. The in-process cutting force is monitored to analyze the relations of the surface roughness and the cutting parameters. The proper cutting condition can be determined easily referring to the minimum use of cutting fluid, and the minimum surface roughness and cutting force of the surface plot. The effectiveness of the obtained surface roughness and cutting force models have been proved by utilizing the analysis of variance at 95% confident level.

Surface Roughness Identification in End Milling Using Vibration Signals and Fuzzy Clustering

2016 ◽  
Author(s):  
Issam Abu-Mahfouz ◽  
Amit Banerjee ◽  
A. H. M. Esfakur Rahman
Keyword(s):  
Surface Roughness ◽  
Fuzzy Clustering ◽  
Wavelet Transforms ◽  
Fourier Transforms ◽  
End Milling ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machined Surface ◽  
Vibration Signals

The study presented involves the identification of surface roughness in Aluminum work pieces in an end milling process using fuzzy clustering of vibration signals. Vibration signals are experimentally acquired using an accelerometer for varying cutting conditions such as spindle speed, feed rate and depth of cut. Features are then extracted by processing the acquired signals in both the time and frequency domain. Techniques based on statistical parameters, Fast Fourier Transforms (FFT) and the Continuous Wavelet Transforms (CWT) are utilized for feature extraction. The surface roughness of the machined surface is also measured. In this study, fuzzy clustering is used to partition the feature sets, followed by a correlation with the experimentally obtained surface roughness measurements. The fuzzifier and the number of clusters are varied and it is found that the partitions produced by fuzzy clustering in the vibration signal feature space are related to the partitions based on cutting conditions with surface roughness as the output parameter. The results based on limited simulations are encouraging and work is underway to develop a larger framework for online cutting condition monitoring system for end milling.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

The Analysis of Tool Wear in Milling CFRP with Different Diamond Coated Tool

2015 ◽  
Vol 667 ◽  
pp. 231-236 ◽  
Author(s):  
Xiao Fan Yang ◽  
You Sheng Li ◽  
Guo Hong Yan ◽  
Ju Dong Liu ◽  
Dong Min Yu
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
Milling Process ◽  
Cutting Condition ◽  
End Mill ◽  
Reinforced Plastics ◽  
Right Hand ◽  
Coated Tool ◽  
New Type ◽  
Fiber Reinforced Plastics

Carbon fiber-reinforced plastics (CFRP) are typical difficult-to-machine materials, which is easy to produce many defects such as burrs, dilacerations, layering in milling process. And selecting the appropriate cutting tool has become the key to machining CFRP with high quality and efficiency. In the paper, the machining principle of milling CFRP with new type end mill was analyzed. The diamond coating of general right-hand end mill, cross-flute router and fine-cross-nick router were used to cutting CFRP under the same cutting condition. Through the comparative analysis of the workpiece’s surface quality and tool wear, it concluded that: compared with right-hand diamond coated end mill, cross-flute diamond coated router or fine-cross-nick diamond coated router could effectively suppress the appearance of burrs and dilacerations; abnormal coating peeling appeared in the flank face of right-hand diamond coated end mill, forming the boundary wear, which accelerated wear failure; the flank wear of diamond coated cross-flute router and fine-cross-nick router were both abrasive wear. Due to having more cutting edge than cross-flute router in cutting process, the flank wear of fine-cross-nick router was slower, and the tool life was longer. So it was more suitable for cutting CFRP.

Surface Roughness Analysis for Radius End Mill in Cross Feed Direction Both Contour and Scanning Line Machinings

2020 ◽  
Author(s):  
Hirohisa Narita
Keyword(s):  
Surface Roughness ◽  
Inclination Angle ◽  
End Milling ◽  
Contour Line ◽  
End Mill ◽  
Good Surface ◽  
Corner Radius ◽  
Feed Direction ◽  
Scanning Line ◽  
Influence Degree

Abstract An optimum experimental condition, which realize good surface roughness in cross direction both contour and scanning lines, for radius end mill against some inclined surfaces is obtained and some features is these cutting processes is discussed in this paper. The optimum experimental condition, which consists of cutting type (or feed direction), spindle speed, feed rate, depth of immersion, inclination angle, corner radius of end mill and cross feed, is obtained and the influence degree of these parameters is calculated by using Taguchi method. The experiment is carried out based on L18 orthogonal array. Based on the influence degree and geometric contact status due to unique shape of radius end mill, some feature of radius end milling is introduced. As a result of the contour line machining, a scallop height is very influenced by the inclination angle and the corner radius, and surface machined by bottom edge must not be remained. Regarding the scanning line machining, “go-up” is good for the feed direction. Big corner radius is also suitable because side edge does not contact to workpiece. In other words, the cutting force in radial direction becomes small. Furthermore, the surface roughness of the scanning line machining is smaller than the one of the contour line machining.

Development of the cBN Electroplated End-Mill for High Precision Machining of CFRP

2020 ◽  
Author(s):  
Shinnosuke Yamashita ◽  
Tatsuya Furuki ◽  
Hiroyuki Kousaka ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
...  
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Drop Out ◽  
End Mill ◽  
Machined Surface ◽  
Side Milling ◽  
Reinforced Plastics ◽  
Milled Surface ◽  
Grinding Conditions ◽  
Grinding Tool

Abstract Recently, the demand of carbon fiber reinforced plastics (CFRP) has been rapidly increased in various fields. In most cases, CFRP products requires a finish machining like cutting or grinding. In the case of an end-milling, burrs and uncut fibers are easy to occur. On the other hand, a precise machined surface and edge will be able to obtain by using the grinding tool. Therefore, this research has been developed a novel the cBN electroplated end-mill that combined end-mill and grinding tool. In this report, the effectiveness of developed tool was investigated. First, the developed tool cut the CFRP with side milling. As the result, the cBN abrasives that were fixed on the outer surface of developed tool did not drop out. Next, the end-milled surface of CFRP was ground with the developed tool under several grinding conditions based on the Design of Experiment. Consequently, the optimum grinding condition that can obtain the sharp edge which does not have burrs and uncut fibers was found. However, surface roughness was not good enough. Thus, an oscillating grinding was applied. In addition, the theoretical surface roughness formula in case using the developed tool was formularized. As the result, the required surface roughness in the airplane field was obtained.

Sign in / Sign up

Export Citation Format

Share Document