Modelling and characterisation of roughness of moulds produced by high-speed machining with ball-nose end mill

Cusps and scallops of hardened steel moulds produced by high-speed milling using a ball-nose end mill were mathematically modelled, characterised by microscopy and experimentally validated. The experimental results show that the part material is crushed or ploughed near the cutter centre, where the cutting speed is very low. This kinematic singularity, associated with tool feed, compresses and bends the ball-nose end mill axially. Because of this double effect, the end mill marks on the part at the end of the milling path cause surface damage and dimensional errors to the hardened mould. A mathematical model may predict the formation of the cusps and scallops and be of use in computer numerical control or computer-aided manufacturing programming to obtain the desired part topography.

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A Model of Cutting Forces for Ball End Mill in High Speed Machining

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.97-101.3108 ◽

2010 ◽

Vol 97-101 ◽

pp. 3108-3112

Author(s):

Bing Yan ◽

Chao Hui Xu ◽

Wei Wang

Keyword(s):

High Speed ◽

End Milling ◽

Cutting Speed ◽

High Speed Machining ◽

End Mill ◽

Cutting Mechanism ◽

Ball End Mill ◽

High Speed Cutting ◽

The Relationship ◽

Machining Characteristics

The machining characteristics of hardened still for mould and die greatly affect the accuracy and productivity in industry. The physical modeling and simulation of ball end milling is investigated in this paper. The influence of cutting speed to the cutting mechanism in high speed cutting is taken into account and the momentum force of chip is introduced into the model. By analyzing the shape of the chips the relationship between the cutting speed and shear angle is obtained. The model has been tested on 718HH, with appropriate Seco tools. The validation shows that the adjustment between the model and the real force is adequate, both in shape and magnitude.

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High-Speed Milling Using a Developed Desktop Machine Tool

International Journal of Automation Technology ◽

10.20965/ijat.2010.p0103 ◽

2010 ◽

Vol 4 (2) ◽

pp. 103-109 ◽

Cited By ~ 2

Author(s):

Hideharu Kato ◽

◽

Kazuhiro Shintani ◽

Kazuo Iwata ◽

Keyword(s):

Surface Roughness ◽

Machine Tool ◽

High Speed ◽

Cutting Speed ◽

High Speed Machining ◽

End Mill ◽

Machining Performance ◽

High Speed Milling

The demand for compact products has raised the need for high-speed machining. In this study, we have designed and produced a desktop machine tool and investigated its high-speed machining performance using a small end mill. The size of the developed machine tool is 300×400×340mm, and the weight is 50 kg. This machine could reach a cutting speed of 25.0 m/s using a 1.7 mm diameter tool. High-speed milling with this machine produced a surface roughness of 0.6 µmRz without tearing. In addition, deformed layers produced at cutting speed of 25.0 m/s was thinner than that at cutting speed of 2.5 m/s. It was confirmed that the thickness of deformed layers at 25.0 m/s was 0.6 µm.

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Research on High-Speed Cutting of Cr12MoV Hardened Steel - A Review

Recent Patents on Engineering ◽

10.2174/1872212115999201201111251 ◽

2020 ◽

Vol 15 ◽

Author(s):

Fei Sun ◽

Guohe Li ◽

Qi Zhang ◽

Meng Liu

Keyword(s):

High Speed ◽

Cutting Temperature ◽

High Hardness ◽

High Strength ◽

Hardened Steel ◽

Parameters Optimization ◽

Future Research ◽

High Speed Machining ◽

Machined Surface ◽

Stamping Die

: Cr12MoV hardened steel is widely used in the manufacturing of stamping die because of its high strength, high hardness, and good wear resistance. As a kind of mainstream cutting technology, high-speed machining has been applied in the machining of Cr12MoV hardened steel. Based on the review of a large number of literature, the development of high-speed machining of Cr12MoV hardened steel was summarized, including the research status of the saw-tooth chip, cutting force, cutting temperature, tool wear, machined surface quality, and parameters optimization. The problems that exist in the current research were discussed and the directions of future research were pointed out. It can promote the development of high-speed machining of Cr12MoV hardened steel.

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A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.576.60 ◽

2012 ◽

Vol 576 ◽

pp. 60-63 ◽

Cited By ~ 7

Author(s):

N.A.H. Jasni ◽

Mohd Amri Lajis

Keyword(s):

Surface Roughness ◽

High Speed ◽

End Milling ◽

Cutting Speed ◽

Hardened Steel ◽

Depth Of Cut ◽

Feed Speed ◽

Radial Depth ◽

Aisi D2 ◽

Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

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Microstructural study of adiabatic shear bands formed in serrated chips during high-speed machining of hardened steel

Journal of Materials Science ◽

10.1007/s10853-008-3001-7 ◽

2009 ◽

Vol 44 (3) ◽

pp. 897-902 ◽

Cited By ~ 14

Author(s):

C. Z. Duan ◽

Y. J. Cai ◽

M. J. Wang ◽

G. H. Li

Keyword(s):

High Speed ◽

Shear Bands ◽

Hardened Steel ◽

Adiabatic Shear ◽

High Speed Machining ◽

Adiabatic Shear Bands ◽

Microstructural Study ◽

Serrated Chips

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Flank Wear Modelling in High Speed Hard Milling of AISI D2 Steel

International Journal of Engineering Materials and Manufacture ◽

10.26776/ijemm.05.02.2020.03 ◽

2020 ◽

Vol 5 (2) ◽

pp. 50-54

Author(s):

Muataz Al Hazza ◽

Khadijah Muhammad

Keyword(s):

Statistical Analysis ◽

Wear Rate ◽

Taguchi Method ◽

Feed Rate ◽

High Speed ◽

Flank Wear ◽

Cutting Speed ◽

Depth Of Cut ◽

High Speed Machining ◽

Aisi D2

High speed machining has many advantages in reducing time to the market by increasing the material removal rate. However, final surface quality is one of the main challenges for manufacturers in high speed machining due to the increasing of flank wear rate. In high speed machining, the cutting zone is under high pressure associated with high temperature that lead to increasing of the flank wear rate in which affect the final quality of the machined surface. Therefore, one of the main concerns to the manufacturer is to predict the flank wear to estimate and predict the surface roughness as one of the main outputs of the machining processes. The aim of this study is to determine experimentally the optimum cutting parameters: depth of cut, cutting speed (Vc) and feed rate (f) that maintaining low flank wear (Vb). Taguchi method has been applied in this experiment. The Taguchi method has been universally used in engineering analysis. JMP statistical analysis software is used to analyse statically the development of flank wear rate during high speed milling of hardened steel AISI D2 to 60 HRD. The experiment was conducted in the following boundaries: cutting speed 200-400 m/min, feed rate of 0.01-0.05 mm/tooth and depth of cut of 0.1-0.2 mm. Analysis of variance ANOVA was conducted as one of important tool for statistical analysis. The result showed that cutting speed is the most influential input factors with 70.04% contribution on flank wear.

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Investigation of Temperature and Stress Distribution on High Speed Machining of Ti6Al4V and 316L Steel Biomaterials Using Explicit Dynamic Analysis

Materials Science Forum ◽

10.4028/www.scientific.net/msf.889.84 ◽

2017 ◽

Vol 889 ◽

pp. 84-89

Author(s):

Pandithevan Ponnusamy ◽

Mullapudi Joshi

Keyword(s):

Dynamic Analysis ◽

Mechanical Behaviour ◽

High Speed ◽

Cutting Speed ◽

Surgical Instruments ◽

Interface Temperature ◽

High Speed Machining ◽

316L Steel ◽

Explicit Dynamic ◽

Cutting Speeds

In high speed machining, to dynamically control the mechanical behaviour of the materials, it is essential to control temperature, stress and strain by appropriate speed, feed and depth of cut. In the present work, to predict the mechanical behaviour of Ti6Al4V and 316L steel bio-materials an explicit dynamic analysis with different cutting speeds was carried out. Orthogonal cutting of 316L steel and Ti6Al4V materials with 720 m/min, 900 m/min and 1200 m/min cutting speeds was performed, and the distribution of stress and temperature was investigated using Jonson-Cook material model. Additionally, the work aimed at determining the effect of cutting speed on work piece temperature, when cutting is carried out continuously. From the investigation, it was found that, while machining Ti6Al4V material, for the increase in cutting speed there was increase in tool-chip interface temperature. Specifically, this could found till the cutting speed 900 m/min. But, there was a decrease in tool-chip interface temperature for the increase in speed from 900 m/min to 1200 m/min. Similarly for 316L steel, the tool-chip interface temperature increased when increasing the cutting speed till 900 m/min. But reduction in temperature from 650 °C to 500 °C for steel and 1028 °C to 990 °C for Ti6Al4V were found, when the cutting speed increased from 900 m/min to 1200 m/min. The study can be used to conclude, at what temperature range the adoption of material with controlled shape and geometry is possible for potential applications like, prosthetic design and surgical instruments prior to fabrications.

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High Speed Machining: A Review from a Viewpoint of Chip Formation

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.188.578 ◽

2011 ◽

Vol 188 ◽

pp. 578-583 ◽

Cited By ~ 7

Author(s):

Toshiyuki Obikawa ◽

Masahiro Anzai ◽

Tsuneo Egawa ◽

Norihiko Narutaki ◽

Kazuhiro Shintani ◽

...

Keyword(s):

Tool Wear ◽

Life Span ◽

High Speed ◽

Cutting Speed ◽

Strong Nonlinearity ◽

High Speed Machining ◽

Cast Irons ◽

Sliding Test ◽

Cutting Experiments ◽

Cutting Speeds

This paper describes strong nonlinearity in log V-log L relationship, which is often found in machining of supperalloys, titanium alloys, hardened steels, cast irons, etc. The nonlinearity plays an important and favorable role in extension of life-span cutting distance at higher cutting speeds; that is, in a certain range of cutting speed, life-span cutting distance increases with cutting speed. Results of tool wear in a sliding test and cutting experiments, which showed the evidences of strong nonlinearity, were investigated and the mechanisms causing the nonlinearity were discussed.

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