An approach to residual stress measurement in ball-end milling process on Ti-6Al-4V ELI titanium alloy

This paper proposes a method to simulate residual stress induced by end milling process via 3-D FEM. First, Johnson-Cook material model parameters for a Japanese type of alloy steel (SCM440H) were extracted by a combination method. With the material model parameters, symmetrical end milling process for plate of SCM440H was simulated by FE software to get the residual stress distribution in the machined workpiece. Residual stress measurement experiment was carried out after end milling process to be compared with simulation result to verify the method, which proved that high simulation accuracy can be obtained by extracted material model parameters.

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Geometrical Modeling of Tool-Workpiece Contact Zone and Chip Formation in Finish Ball End Milling Process with Tool Inclination Angles

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.693.788 ◽

2016 ◽

Vol 693 ◽

pp. 788-794

Author(s):

Xiao Xiao Chen ◽

Jun Zhao

Keyword(s):

Contact Zone ◽

Measurement Method ◽

End Milling ◽

Milling Process ◽

Ball End Milling ◽

Geometrical Modeling ◽

Section Area ◽

Inclination Angles ◽

Area And Perimeter ◽

End Milling Process

The tool-workpiece contact zone is an important issue in the ball end milling process. This paper investigated the effects of tool inclination angles on the tool-workpiece contact zone, and variations of the cutting section area and perimeter with the increasing tilt and lead angles were also analyzed by geometrical modeling and measurement method for ball end milling process. The appropriate tool inclination angles, which could avoid the extrusion and friction between tool tip and the uncut materials, shorten the loading time on the cutting flute, and decrease the maximum cutting forces, could be preferentially selected according to the distribution characteristics of the tool-workpiece contact zone and the variations of the cutting section area and perimeter corresponding to various tool postures.

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Prediction of surface roughness in ball-end milling process by utilizing dynamic cutting force ratio

Journal of Intelligent Manufacturing ◽

10.1007/s10845-014-0958-8 ◽

2014 ◽

Vol 28 (1) ◽

pp. 13-21 ◽

Cited By ~ 14

Author(s):

S. Tangjitsitcharoen ◽

P. Thesniyom ◽

S. Ratanakuakangwan

Keyword(s):

Surface Roughness ◽

Cutting Force ◽

End Milling ◽

Milling Process ◽

Ball End Milling ◽

Dynamic Cutting Force ◽

Force Ratio ◽

End Milling Process

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Intelligent Monitoring and Prediction of Surface Roughness in Ball-End Milling Process

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.121-126.2059 ◽

2011 ◽

Vol 121-126 ◽

pp. 2059-2063 ◽

Cited By ~ 3

Author(s):

Somkiat Tangjitsitcharoen ◽

Angsumalin Senjuntichai

Keyword(s):

Surface Roughness ◽

Cutting Force ◽

Prediction Accuracy ◽

End Milling ◽

Milling Process ◽

Ball End Milling ◽

Roughness Model ◽

Force Ratio ◽

Tool Diameter ◽

End Milling Process

In order to realize the intelligent machines, the practical model is proposed to predict the in-process surface roughness during the ball-end milling process by utilizing the cutting force ratio. The ratio of cutting force is proposed to be generalized and non-scaled to estimate the surface roughness regardless of the cutting conditions. The proposed in-process surface roughness model is developed based on the experimentally obtained data by employing the exponential function with five factors of the spindle speed, the feed rate, the tool diameter, the depth of cut, and the cutting force ratio. The prediction accuracy and the prediction interval of the in-process surface roughness model at 95% confident level are calculated and proposed to predict the distribution of individually predicted points in which the in-process predicted surface roughness will fall. All those parameters have their own characteristics to the arithmetic surface roughness and the surface roughness. It is proved by the cutting tests that the proposed and developed in-process surface roughness model can be used to predict the in-process surface roughness by utilizing the cutting force ratio with the highly acceptable prediction accuracy.

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Generalized Mechanistic Force System Model of Ball-End Milling for Sculpture Surface Machining

10.1115/imece2001/med-23303 ◽

2001 ◽

Author(s):

Ismail Lazoglu

Keyword(s):

End Milling ◽

Mechanistic Model ◽

Milling Process ◽

Force System ◽

Workpiece Surface ◽

Surface Machining ◽

Ball End Milling ◽

End Milling Process ◽

Validation Experiments ◽

Good Agreement

Abstract In this paper, a new mechanistic model is developed for the prediction of cutting force system in ball-end milling process. The key feature of the model includes the ability to calculate the workpiece / cutter intersection domain automatically for a given cutter location (CL) file, cutter and workpiece geometries. Moreover, an analytical approach is used to determine the instantaneous chip load and cutting forces. The model also employs a Boolean approach for given cutter, workpiece geometries, and the CL file in order to determine the surface topography and scallop height variations along the workpiece surface which can be visualized in 3-D. Some of the typical results from the model validation experiments performed on Ti-6A1-4V are also reported in the paper. Comparisons of the predicted and measured forces as well as the surface topographies show good agreement.

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Experimental Study on Micro End-Milling Process of Ti-6AL-4V Using Nanofluid Minimum Quantity Lubrication (MQL)

Volume 1: Materials; Micro and Nano Technologies; Properties, Applications and Systems; Sustainable Manufacturing ◽

10.1115/msec2014-4124 ◽

2014 ◽

Cited By ~ 4

Author(s):

Dae Hoon Kim ◽

Pil-Ho Lee ◽

Jung Sub Kim ◽

Hyungpil Moon ◽

Sang Won Lee

Keyword(s):

Surface Roughness ◽

Titanium Alloy ◽

End Milling ◽

Minimum Quantity Lubrication ◽

Milling Process ◽

Minimum Quantity ◽

Nanofluid Minimum Quantity Lubrication ◽

Micro End Milling ◽

Milling Forces ◽

End Milling Process

This paper investigates the characteristics of micro end-milling process of titanium alloy (Ti-6AL-4V) using nanofluid minimum quantity lubrication (MQL). A series of micro end-milling experiments are conducted in the meso-scale machine tool system, and milling forces, burr formations, surface roughness, and tool wear are observed and analyzed according to varying feed per tooth and lubrication conditions. The experimental results show that MQL and nanofluid MQL with nanodiamond particles can be effective to reduce milling forces, burrs and surface roughness during micro end-milling of titanium alloy. In particular, it is demonstrated that smaller size of nanodiamond particles — 35 nm — can be more effective to decrease burrs and surface roughness in the case of nanofluid MQL micro end-milling.

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