scholarly journals Systematic study of the prediction methods for machined surface topography and form error during milling process with flat-end cutter

2017 ◽  
Vol 233 (1) ◽  
pp. 226-242 ◽  
Author(s):  
Xing Zhang ◽  
Wei Zhang ◽  
Jun Zhang ◽  
Bo Pang ◽  
Wanhua Zhao
Keyword(s):  
Evaluation Method ◽  
Strong Dependence ◽  
Reconstruction Algorithm ◽  
Simulation Method ◽  
Milling Process ◽  
Depth Of Cut ◽  
Form Error ◽  
Cutter Runout ◽  
Machined Surface ◽  
Milling Condition

An enhanced time-domain simulation method of cutter/workpiece dynamic engagement during milling process is proposed in this article, which comprehensively considers the effect of multi-order modal characteristics of cutter system and cutter runout including offset and inclination. Based on the cutter dynamic displacement response, this article further presents the machined surface reconstruction algorithm and evaluation method for the form error. This research systematically studies and compares the calculation accuracy between the proposed method and other previous three kinds of methods. The effectiveness of the proposed method has been verified by a series of milling experiments successfully. By comparing with the other three methods, the proposed method shows a high calculation performance, especially under the milling condition with a large axial depth of cut and low damping or stiffness of cutter system. Besides, the results indicate that the form error has a strong dependence characteristic on the milling parameters, particularly on spindle speed. Additionally, cutter runout would easily cause over cut phenomenon on the machined surface and seriously deteriorate the surface roughness.

scholarly journals Surface Integrity Investigation to Determine Rough Milling Effects for Assessment of Machining Allowance for Subsequent Finish Milling of Alloy 718

2021 ◽  
Vol 5 (2) ◽  
pp. 48
Author(s):  
Jonas Holmberg ◽  
Anders Wretland ◽  
Johan Berglund ◽  
Tomas Beno ◽  
Anton Milesic Karlsson
Keyword(s):  
Surface Integrity ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Milling Operations ◽  
Milling Operation ◽  
Machining Allowance ◽  
Rough Milling

The planned material volume to be removed from a blank to create the final shape of a part is commonly referred to as allowance. Determination of machining allowance is essential and has a great impact on productivity. The objective of the present work is to use a case study to investigate how a prior rough milling operation affects the finish machined surface and, after that, to use this knowledge to design a methodology for how to assess the machining allowance for subsequent milling operations based on residual stresses. Subsequent milling operations were performed to study the final surface integrity across a milled slot. This was done by rough ceramic milling followed by finish milling in seven subsequent steps. The results show that the up-, centre and down-milling induce different stresses and impact depths. Employing the developed methodology, the depth where the directional influence of the milling process diminishes has been shown to be a suitable minimum limit for the allowance. At this depth, the plastic flow causing severe deformation is not present anymore. It was shown that the centre of the milled slot has the deepest impact depth of 500 µm, up-milling caused an intermediate impact depth of 400 µm followed by down milling with an impact depth of 300 µm. With merged envelope profiles, it was shown that the effects from rough ceramic milling are gone after 3 finish milling passes, with a total depth of cut of 150 µm.

Corrosion Behaviour and Microhardness during Dry and Flood Milling of Ti-6Al-4V Alloy

2019 ◽  
Vol 796 ◽  
pp. 91-96
Author(s):  
Esther Titilayo Akinlabi ◽  
Ipfi Mathoho ◽  
Mukuna Patrick Mubiayi
Keyword(s):  
Corrosion Resistance ◽  
Cutting Tool ◽  
Corrosion Behaviour ◽  
Milling Process ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Milled Surface ◽  
Milling Condition

Milling process is the removal of unwanted materials so as to produce the required shape. The purpose of this study was to investigate the effect of milling process parameters and the cooling technique on corrosion behaviour and microhardness of TI-6AL-4V. Milling of Ti-6Al-4V was carried out using tungsten carbide cutting tool while varying spindle speed (120,150, and 180 rev/min), depth of cut (1, 1.5 and 2 mm) and the feed rate remained unchanged at 4.6 mm/min. Subsequent to milling, characterization of subsurface microhardness and corrosion behaviour was conducted. It was found that varying spindle speed and depth of cut had an impact on microhardness. Furthermore, it was noticed that the type of milling condition (flood and dry milling) affected the subsurface microhardness and the corrosion behavior. The corrosion resistance of the milled surface was generated at 180 rev/min and 150 rev/min for the dry and flood milling respectively. Furthermore, the most corrosion resistance was obtained at 2 mm and 1.5 mm depth of cut during dry and flood milling respectively.

Технологическое обеспечение качества поверхностного слоя стекловолоконных композитов при концевом фрезеровании

2020 ◽  
Vol 22 (4) ◽  
pp. 31-40
Author(s):  
Andrei Markov ◽  
◽  
Vyacheslav Nekrasov ◽  
Jian Su ◽  
Azhar Salman ◽  
...  
Keyword(s):  
Composite Materials ◽  
End Milling ◽  
Experimental Studies ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Scientific Publications ◽  
Experimental Assembly ◽  
Operation Results

Introduction. Today fiberglass is one of the most common composite materials. Therefore, its mechanical processing continues to be the subject of many studies. In many scientific publications, the influence of cutting modes and structural and geometric parameters of the tool on the roughness of the machined surface, cutting forces and wear of the cutting tool has been established. The purpose of this work is to study the effect of machining modes on delamination and roughness of fiberglass composites during end milling, as well as testing the hypothesis about the effect of torque on the delamination. The relevance of the study is due to the fact that delamination, along with roughness, has a significant impact on the quality of processing and subsequent assembly of the finished product. A criterion is proposed for assessing the magnitude of the delamination of composite materials during its machining. The results of experimental studies of the torque on the cutter, the relative coefficient of delamination and surface roughness from cutting conditions are presented. Methods: factorial experiment using an experimental assembly developed by the authors based on a piezoelectric torque sensor. The installation allows real-time recording of the change in torque during the milling process, depending on the modes of operation. Results and Discussion. A comparative analysis of the obtained dependences showed that the torque is directly related to delamination. To reduce the delamination, the depth of cut should be decreased, and in order to ensure the specified productivity, the feed and the rotational speed of the cutter should be increased. The presented results confirm the prospects of the developed approach aimed at machining new classes of composite materials.

Optimization of the Process Parameters in Milling of Aluminum Alloys

2020 ◽  
Vol 896 ◽  
pp. 293-298
Author(s):  
Nicolae Craciunoiu ◽  
Emil Nicusor Patru ◽  
Adrian Sorin Rosca ◽  
Dumitru Panduru ◽  
Marin Bica
Keyword(s):  
Aluminum Alloys ◽  
Tool Wear ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Experimental Conditions ◽  
Milling Parameters

In order to control the temperature during milling process of aluminum alloys and keeping as minimum as possible, the choice of the cutting parameters and their optimization is very important, both for the tool wear but also for the surface quality of machined surface. The main purpose of this paper is to find the optimum values of the milling parameters (rotational speed and depth of cut) so that the minimum value for the temperature to be obtained. Using adequate experimental conditions with contact measurements techniques (thermocouple K-type) carried out on the some types of aluminum alloys and the appropriate statistical instruments, the most influencing cutting parameters and their values on the cutting temperature can be found. The results are presented both analytical and graphical.

Study on the Machined Surface Geometry Generated by Multi-Axis Ball End Milling Process

2013 ◽  
Vol 770 ◽  
pp. 370-375
Author(s):  
Xiao Xiao Chen ◽  
Jun Zhao ◽  
Yong Wang Dong ◽  
Shuai Liu ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Parameters ◽  
Peak Height ◽  
Milling Process ◽  
Depth Of Cut ◽  
Small Range ◽  
Surface Geometry ◽  
Machined Surface ◽  
Two Parameters

This paper investigated the surface generated by single factor experiment under multi-axis finish milling condition, and the effects of cutting parameters on surface textures, 2D and 3D surface topographies and surface roughness characteristics were analyzed. Surface features evaluation indicators of Ra, Rq, Rt, surface heights histogram, maximum valley depth and maximum peak height corresponding to various cutting parameters were presented and discussed. The machining marks are closely related with tool orientation angles. The orderly distributions of concave and convex patterns on the machined surface are produced by the special cutting orientation of the cutting edges. The feed per tooth, spindle speed, tilt angle, and lead angle apparently affect surface roughness, while depth of cut and radial width of cut have no obvious effects on the surface roughness when the two parameters values vary in a small range.

Physical Simulation of the Cutting Process Induced by Tool Geometric Angle and Cutting Parameters

2012 ◽  
Vol 430-432 ◽  
pp. 715-718 ◽  
Author(s):  
Xue Hui Wang ◽  
Ping Zhou ◽  
Ya Wen Liu ◽  
Ming Jun Dai
Keyword(s):  
Physical Simulation ◽  
Cutting Parameters ◽  
Simulation Method ◽  
Helix Angle ◽  
Rake Angle ◽  
Milling Process ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Solid Carbide

The tool geometric angle and cutting parameters have a significant influence on the titanium alloy milling process by the usage of solid carbide end mills.The physical simulation method was applied to predict the cutting force and temperature by using two comparative sets of simulation data such as the different tool gemetric angle as tool rake angle, helix angle and different cutting parameters such as spindle speed, axial depth of cut, radial depth of cut. Thus are the commonly used methods to simulate and predict the cutting process before the actual production, which can reduce product cost and time.

scholarly journals Surveying the topography and examining the quality of the machined surface of selected hardened steels in the milling process

2021 ◽  
Vol 9 (3B) ◽  
Author(s):  
Jan Duplak ◽  
◽  
Darina Duplakova ◽  
Michal Hatala ◽  
Svetlana Radchenko ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Simulation Method ◽  
Milling Process ◽  
Machined Surface ◽  
Experimental Procedure ◽  
Hard Materials ◽  
The Individual

The article deals with the surface roughness examination of three selected hard materials, that is, K100, 100CrMnMo7, and 16MnCr5, all with a defined hardness of HRC 60. The individual materials were machined using sintered carbide and cermet cutting materials with TiCN and TiN + TiCN + Al2O3 coatings. The research resided in the realization of three experiments. These experiments were carried out by three alternatives differing in the setting of basic cutting parameters. The experimental procedure was realized by the simulation method and direct contact measurement method of surface roughness. From the overall technical evaluation described in the practical part of the article, for the primarily observed parameter, the surface roughness, the least suitable values were obtained in the evaluation of the material from experiment No. 1-K100 with hardness HRC60. The experiments realized and the results achieved show that the machining of tool steels and other superhard materials requires special cutting tools, machines, and the use of progressive technologies, to ensure the production of a dimensionally and qualitatively shaped functional component.

Cutting Parameters Impacting on Tool Wear in Micro End-milling of Tool Steel

2018 ◽  
Author(s):  
Cínthia Soares Manso ◽  
Cleiton Lazaro Fazolo de Assis ◽  
Luciana Wasnievski da Silva de Luca Ramos ◽  
Erik Gustavo Del Conte
Keyword(s):  
Tool Wear ◽  
Tool Steel ◽  
End Milling ◽  
Cutting Parameters ◽  
Milling Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Machined Surface ◽  
Tool Diameter

In micro milling process, the quick wear and premature breakage of tools configure a problem that affects not only the process costs but also the manufacturing quality. This work investigates the influence of the cutting parameters on tool wear and surface roughness in a dry machining of a tool steel H13 workpiece (X40CrMoV5-1). Spindle speed was kept constant (27200 rpm) and two feeds per tooth were applied (1.5 and 3.0 µm) as depth of cut (25 and 30 µm), and variating cut length as well. The wear of the tool top area, tool diameter and nose radius were monitored during micro milling tests. Roughness was evaluated by using a Laser Confocal Microscope. The lower level of feed per tooth and depth of cut showed lower roughness, but a higher tool wear. A balance between cutting parameters and cutting length must be considered to ensure micromachining without severe tool wear and preserve microchannel features along its machined surface.

Analytical Modeling and Simulation of the Envelope Surface in Five-Axis Flank Milling With Cutter Runout

2012 ◽  
Vol 134 (2) ◽  
Author(s):  
Yuwen Sun ◽  
Qiang Guo
Keyword(s):  
Flank Milling ◽  
Error Prediction ◽  
Surface Model ◽  
Form Error ◽  
Cutter Runout ◽  
Machined Surface ◽  
Rotation Surface ◽  
Envelope Surface ◽  
Tool Positioning ◽  
Five Axis

The cutter runout effect has significant influence on the shape of the cutter swept surface and the machining surface quality. Due to the existence of cutter runout effect, the shape and position of envelope surface formed by each cutter edge are different from others. Hence, it is necessary to integrate the cutter runout effect and its resulting compound effects of all cutter edges into envelope surface modeling and form error prediction for five-axis milling. This paper establishes the envelope surface model considering cutter runout effect in five-axis flank milling based on the relative motion analysis of the cutter and part. In this model, the cutter runout is defined by three parameters, including inclination angle, location angle, and offset value, and the cutter runout effect is subsequently integrated into the model by using the cutter edge as the generatrix of cutter rotation surface. Then, the influence of each runout parameter on the shape of envelope surface formed by each cutter edge as well as the resulting form error in milling is investigated. Also, the compound effects of all cutter edges on the final resulting geometric errors of the machined surface are analyzed. Finally, simulations and machining experiment are conducted for a specific ruled surface, and the results validate the effectiveness and feasibility of proposed envelope surface model considering cutter runout effect. It is suitable to be used in tool positioning, tool installation adjustment, and forming error prediction in flank milling process with cutter runout.

Experimental Study on Milling Hardened SKD Steel Using Micro CBN Ball-End Mills

2010 ◽  
Vol 126-128 ◽  
pp. 773-778
Author(s):  
Yung Tien Liu ◽  
Neng Hsin Chiu ◽  
Yen Chun Lin ◽  
Chih Liang Lai ◽  
Yu Fu Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Milling Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Machined Surface ◽  
Performance Function ◽  
End Mills

Micro ball-end milling process features the ability of machining complex surfaces, precision machining accuracy, and excellent machined surface roughness. However, because the diameter of a micro milling tool is very small, a rapid progress of tool wear or even tool breakage usually happens when machining a high-strength hardened mold steel using improper machining parameters. As a result, the machining cost would rise due to the quality defect in machined workpiece. In this study, to investigate how the machining parameters affect the cutting behaviors, a series of experiments using micro CBN ball-end mills with a diameter of 0.5 mm were performed to cut the SKD11 mold steel with hardness of HRC 61. The machining parameters are selected as the feeding speed (f) being 840, 960 and 1,080 mm/min, depth of cut (ap) being 30, 45, 60 μm, and spindle speed (vs) being fixed as 30,000 rpm. According to the experimental results, the measured three-axis cutting forces, flank wears, and surface roughness of machined workpiece are highly related to the cutting length. It is expected that the measured results can be used to construct a performance function of a micro ball-end tool. With referring to the performance function, the tool life can be well expected, and thus a progress in machining efficiency without tool failure can be achieved.

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