Optimum end milling tool path and machining parameters for micro Laval nozzle manufacturing

2015 ◽  
Vol 231 (10) ◽  
pp. 1703-1712 ◽  
Author(s):  
Yukui Cai ◽  
Zhanqiang Liu ◽  
Zhenyu Shi ◽  
Qinghua Song ◽  
Yi Wan
Keyword(s):  
Surface Roughness ◽  
Laval Nozzle ◽  
Tool Path ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Performance Parameters ◽  
Tool Paths ◽  
Milling Tool

Cutting tool path has significant effects on the performance of micro nozzles manufactured by micro machining. Different tool paths induced different directions of surface roughness. As for it, the manufacturers need to obtain optimal cutting tool path and cutting parameters. In this article, optimum machining parameters for the fabrication of micro Laval nozzle with two different end milling tool paths are presented. First, surface roughness models for different types of cutting tool paths are proposed. A case of machined nozzle surface is then given to verify the applicability of the developed roughness model. Second, theoretical profile geometries for the Laval nozzle to be manufactured are designed. Third, the influences of surface roughness on the nozzle performance parameters including total pressure, average outlet velocity and thrust are investigated through computational fluid dynamic analysis. Simulated performance parameters are contrasted with their theoretical values. It is found that for different tool paths, the nozzle of axial tool path has larger total pressure and average outlet velocity than that of circular tool path. Moreover, with surface roughness increasing, thrust decreases obviously when surface roughness Rz is larger than 4.8 μm. Micro end milling experiments based on axial tool path are then performed, and the optimum cutting parameters are obtained. Finally, a nozzle was manufactured with the axial tool path as well as the optimized cutting parameters.

Influence of Machining Strategies on Surface Roughness in Ball End Milling of Inclined Surfaces

2012 ◽  
Vol 488-489 ◽  
pp. 836-840 ◽  
Author(s):  
S. Shajari ◽  
M.H. Sadeghi ◽  
H. Hassanpour ◽  
B. Jabbaripour
Keyword(s):  
Surface Roughness ◽  
Tool Path ◽  
End Milling ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Scallop Height ◽  
Inclined Surfaces ◽  
Milling Operation ◽  
Variable Surface ◽  
Machining Strategies

Inclined surfaces are commonly used in the aerospace and die/mold industries. For machining this kind of surfaces, many aspects have to be considered as machinability considerations including milling strategies, machining parameters and etc. In machining, achieving better quality is challenging task. Various tool-path strategies during milling operation leads to variable surface roughness on machined samples. The objective of this study is to analyze different machining strategies in 3-axis milling of a typical curved geometry part. The machining parameters used in this study, are cutting speed, feedrate and stepover. This paper also presents an approach to develop a mathematical model for measuring Scallop height size and distribution for different machining strategies to show that Scallop height size has direct relation with Surface roughness measurements in each strategy. Finally the optimized strategy based on the results was determined.

The Effect of the Cutting Parameters on the Machined Surface Roughness

2017 ◽  
Vol 260 ◽  
pp. 219-226 ◽  
Author(s):  
Viktors Gutakovskis ◽  
Eriks Gerins ◽  
Janis Rudzitis ◽  
Artis Kromanis
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Tool Geometry ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness

From the invention of turning machine or lathe, some engineers are trying to increase the turning productivity. The increase of productivity is following after the breakout in instrumental area, such as the hard alloy instrument and resistance to wear cutting surfaces. The potential of cutting speed has a certain limit. New steel marks and cutting surfaces types allow significantly increase cutting and turning speeds. For the most operation types the productivity increase begins from the feeding increase. But the increase of feeding goes together with machined surface result decreasement. Metal cutting with high feeding is one of the most actual problems in the increasing of manufacturing volume but there are some problems one of them is the cutting forces increasement and larger metal removal rate, which decrease the cutting tool life significantly. Increasing of manufacturing volume, going together with the cutting instrument technology and material evolution, such as the invention of the carbide cutting materials and wear resistant coatings such as TiC and Ti(C,N). Each of these coating have its own properties and functions in the metal cutting process. Together with this evolution the cutting tool geometry and machining parameters dependencies are researched. Traditionally for the decreasing the machining time of one part, the cutting parameters were increased, decreasing by this way the machining operation quantity. In our days the wear resistance of the cutting tools increasing and it is mostly used one or two machining operations (medium and fine finishing). The purpose of the topic is to represent the experimental results of the stainless steel turning process, using increased cutting speeds and feeding values, to develop advanced processing technology, using new modern coated cutting tools by CVD and PVD methods. After investigation of the machined surface roughness results, develop the mathematical model of the cutting process using higher values of the cutting parameters.

scholarly journals The Effect of the Feed Direction on the Micro- and Macro Accuracy of 3D Ball-end Milling of Chromium-Molybdenum Alloy Steel

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4038
Author(s):  
Balázs Mikó ◽  
Bálint Varga ◽  
Wojciech Zębala
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Tool Path ◽  
End Milling ◽  
Cutting Parameters ◽  
Machining Process ◽  
Free Form ◽  
Dimensional Error ◽  
Ball End Milling ◽  
Free Form Surfaces

The machining of free form surfaces is one of the most challenging problems in the field of metal cutting technology. The produced part and machining process should satisfy the working, accuracy, and financial requirements. The accuracy can describe dimensional, geometrical, and surface roughness parameters. In the current article, three of them are investigated in the case of the ball-end milling of a convex and concave cylindrical surface form 42CrMo4 steel alloy. The effect of the tool path direction is investigated and the other cutting parameters are constant. The surface roughness and the geometric error are measured by contact methods. Based on the results, the surface roughness, dimensional error, and the geometrical error mean different aspects of the accuracy, but they are not independent from each other. The investigated input parameters have a similar effect on them. The regression analyses result a very good liner regression for geometric errors and shows the importance of surface roughness.

Investigation on Effect of Machining Parameters of End Milling on Surface Finish and Temperature Using Taguchi Technique

2016 ◽  
Vol 16 (4) ◽  
pp. 255-261
Author(s):  
Tamiloli N ◽  
Venkatesan J
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Milling Process ◽  
Machining Parameters ◽  
Cutting Zone ◽  
Machining Optimization ◽  
Quality Surface

AbstractMachining of alloy materials at high cutting speeds produces high temperatures in the cutting zone, which affects the surface quality. Thus, developing a model for estimating the cutting parameters and optimizing this model to minimize the surface roughness and cutting temperatures becomes utmost important to avoid any damage to the quality surface. This paper presents the development of new models and optimizing these models of machining parameters to minimize the surface roughness and cutting temperature in end milling process by Taguchi method with the statistical approach. Two objectives have been considered, minimum arithmetic mean roughness (Ra) and cutting temperature. Due to the complexity of this machining optimization problem, a single objective Taguchi method has been applied to resolve the problem, and the results have been analyzed.

scholarly journals Influence of Tool Path Strategies and Pocket Geometry on Surface Roughness in Pocket Milling

2020 ◽  
Vol 9 (2) ◽  
pp. 884-888
Keyword(s):  
Surface Roughness ◽  
Tool Path ◽  
Cutting Tool ◽  
Cutting Parameters ◽  
Milling Process ◽  
End Mill ◽  
Roughness Measurement ◽  
Machining Processes ◽  
Pocket Milling ◽  
Carbide Insert

This paper discusses the effect of tool path strategies and pocket geometry to surface roughness due to pocket milling process. The machining processes have been performed on mould steel DF2 using carbide insert end mill as the cutting tool. The cutting parameters for this experiment were kept constant while the variables were cutting tool, path strategies and pocket geometries at three levels each. The effectiveness of different tool path strategy and different pocket geometry is evaluated in terms of measured surface roughness (Ra) of the workpiece. The grade of a pocket is directly proportional with its surface roughness. The lowest surface roughness measurement was produced by pocket geometry B with parallel spiral cutting tool path strategy.

Surface quality analysis in ball end milling of Inconel 718 cantilevers by response surface methodology

2016 ◽  
Vol 231 (4) ◽  
pp. 628-640 ◽  
Author(s):  
Nandkumar N Bhopale ◽  
Raju S Pawade ◽  
Suhas S Joshi
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Inconel 718 ◽  
Tool Path ◽  
End Milling ◽  
Machining Parameters ◽  
Machined Surface ◽  
Ball End Milling ◽  
Fixed End ◽  
Side Flow

The ball end milling process is commonly used for generating complex three-dimensional sculptured surfaces with definite curvature. In such cases, variation of surface properties along with the machined surface is not well understood. Therefore, this article investigates the effect of machining parameters on the quality of surface in ball end milling of thin-shaped cantilever of Inconel 718. A distinct variation is also observed in the measured values of deflection of workpiece: surface roughness and surface damage in different regions, that is, fixed end, mid portion and free end of machined surface. The experiments were conducted according to the central composite design with four factors, namely, cutting speed, feed, workpiece thickness and workpiece inclination with tool path orientation. It is observed that the process parameters have statistically significant effect on machined surface of Inconel 718. Horizontal tool path condition during milling is most favourable in all aspects of surface quality with high speed and lower feed. The surface roughness values at the fixed end of plate are less as compared with that of mid portion and free end sides. Scanning electron microscope images show various defects such as side flow, smeared layer, microparticle, grooves and feed marks.

Optimisation of tool path for wood machining on CNC machines

2016 ◽  
Vol 231 (1) ◽  
pp. 72-87 ◽  
Author(s):  
A Petrovic ◽  
L Lukic ◽  
S Ivanovic ◽  
A Pavlovic
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Tool Path ◽  
Cutting Parameters ◽  
Machining Process ◽  
Machining Parameters ◽  
Wood Processing ◽  
Tool Paths ◽  
Radial Depth ◽  
Wood Machining

Peripheral pocket or contour milling in wood machining, using flat end milling tool, can be performed with different tool paths. Technology designers of multi axis CNC wood machining use their experience and intuition to choose some of the options offered by CAM systems that determine the final shape of tool path, thus the generated tool path largely depend on individual judgment. Minimum cutting force, maximum dynamic stability of the process and minimum tool wear are achieved, or some other technological requirements are met, by using optimal tool path. Tool path optimisation is based on analysis of possible tool paths and determination of cutting parameters which are dependable of chosen tool path and are affecting the main wood processing factors. Axial and radial depth of cut, engagement angle, feed and feed rate profile are identified as key parameters dependable of tool path, and their values and variations along the tool path influence the cutting speed, tool wear and cutting force. Knowledge of values and changes of those key machining parameters along the tool path is necessary for simulation and monitoring of the main cutting factors during the wood machining process. NC code transformation methodology and generation of tool path parameters necessary for calculating all elements needed for tool movement simulation from given NC programs are shown. Blank and tool mathematical description are used with tool movement information for simulation of wood machining process. Simulation of cutting parameters and their variation along the tool path, presented in this paper, can be used as bases for development of methodology for choosing the most adequate tool path for wood machining of given contour considering minimum cutting force and cutting force variation, minimum tool wear, maximum productivity or some other criteria.

The Influence of Feed per Tooth Variation on Surface Roughness of 7136 Aluminum Alloy in End Milling

2015 ◽  
Vol 808 ◽  
pp. 34-39 ◽  
Author(s):  
Alina Bianca Bonţiu Pop ◽  
Mircea Lobonţiu
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Aircraft Industry ◽  
New Material ◽  
Experimental Researches ◽  
The Given

This paper fits into an experimental researches complex, regarding the surface roughness dependency on the cutting parameters of 7136 aluminum alloy machining. The purpose of this paper is to identify by experiments the influence of feed per tooth variation on surface roughness. A range of feed per tooth was used while the cutting speed and the cutting depth were constrained per minimum and maximum requirements defined for the given cutting tool. The experiments were conducted on Al7136 because it is a new material and I have identified the need for its use in the aircraft industry.

Application of Taguchi’s Method for Study of Machining Parameters on Surface Roughness of 7136 Aluminum Alloy in End Milling

2015 ◽  
Vol 809-810 ◽  
pp. 123-128 ◽  
Author(s):  
Alina Bianca Bonţiu Pop
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Process Parameters ◽  
End Milling ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Future Research ◽  
Depth Of Cut ◽  
Machining Parameters

Starting with the necessity to identify the optimum values of the cutting parameters which are affecting the surface quality, it is appropriate to use the design of experiment techniques to conduct the experiments. Previous researches [1] focused on the investigation of the effects of machining parameters on surface roughness. In this paper, the experiments were conducted based on the established Taguchi’s technique, L8 orthogonal array using Minitab-17 statistical software. Three machining parameters are chosen as process parameters: Cutting Speed, Feed per tooth and Depth of cut. The orthogonal matrix includes these three factors set for analysis, each with 2 levels associated. The level of influence that the process parameters exert on the surface roughness is analyzed by Taguchi method data analysis. In this case the signal to noise ratio was tacked into account. Also, the recommended configuration regarding the optimum values of these parameters was determined as well as the interactions between them, in order to obtain better surface roughness for 7136 aluminum alloy machining. The final results will be used as data for future research.

scholarly journals Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1783
Author(s):  
Hamza A. Al-Tameemi ◽  
Thamir Al-Dulaimi ◽  
Michael Oluwatobiloba Awe ◽  
Shubham Sharma ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Good Practice ◽  
Cutting Tools ◽  
Statistical Design ◽  
Cutting Parameters ◽  
Statistical Design Of Experiments ◽  
Hole Quality ◽  
Coated Tools ◽  
Tool Coating

Aluminum alloys are soft and have low melting temperatures; therefore, machining them often results in cut material fusing to the cutting tool due to heat and friction, and thus lowering the hole quality. A good practice is to use coated cutting tools to overcome such issues and maintain good hole quality. Therefore, the current study investigates the effect of cutting parameters (spindle speed and feed rate) and three types of cutting-tool coating (TiN/TiAlN, TiAlN, and TiN) on the surface finish, form, and dimensional tolerances of holes drilled in Al6061-T651 alloy. The study employed statistical design of experiments and ANOVA (analysis of variance) to evaluate the contribution of each of the input parameters on the measured hole-quality outputs (surface-roughness metrics Ra and Rz, hole size, circularity, perpendicularity, and cylindricity). The highest surface roughness occurred when using TiN-coated tools. All holes in this study were oversized regardless of the tool coating or cutting parameters used. TiN tools, which have a lower coating hardness, gave lower hole circularity at the entry and higher cylindricity, while TiN/TiAlN and TiAlN seemed to be more effective in reducing hole particularity when drilling at higher spindle speeds. Finally, optical microscopes revealed that a built-up edge and adhesions were most likely to form on TiN-coated tools due to TiN’s chemical affinity and low oxidation temperature compared to the TiN/TiAlN and TiAlN coatings.

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