Evaluation and Modeling of the Effect of Tool Edge Radius on Machined Surface Roughness in Turning UNS A92024-T351 Aluminum Alloy

By using experiment cutter edge topography obtained by super depth three-dimension microscope, fits the cutter edge curve and calculate experiment cutter edge radius value; by high speed milling hardened steel experiment, individually researches cutter edge and cutting parameters influence on machined surface in high speed milling hardened steel with end-milling cutter and ball-end milling cutter. The experiment analysis results show that under the same cutting parameters condition, machined surface roughness in high speed end-milling cutter milling is better than in high speed ball-end milling; within experiment selected cutting parameter range, cutter edge radius is the main influence factor on machined surface roughness in high speed end- milling hardened steel, while the influence on machined surface roughness in high speed ball-end milling hardened steel is not obvious. In end-milling, when edge radius and milling depth are in the same order magnitude or the difference is not obvious, milling depth should be a little bigger than selected cutter edge radius value.

Download Full-text

Experiment Research of Cutter Edge and Cutting Parameters Influence on Machined Surface Roughness for High Speed Milling Hardened Steel

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.670.70 ◽

2013 ◽

Vol 670 ◽

pp. 70-75 ◽

Cited By ~ 1

Author(s):

Wei Zhang ◽

M.L. Zheng ◽

M.M. Cheng ◽

W.T. Wang

Keyword(s):

Surface Roughness ◽

High Speed ◽

End Milling ◽

Cutting Parameters ◽

Hardened Steel ◽

Machined Surface ◽

High Speed Milling ◽

Ball End Milling ◽

Edge Radius ◽

Machined Surface Roughness

By using experiment cutter edge topography obtained by super depth three-dimension microscope, fits the cutter edge curve and calculate experiment cutter edge radius value; by high speed milling hardened steel experiment, individually researches cutter edge and cutting parameters influence on machined surface in high speed milling hardened steel with end-milling cutter and ball-end milling cutter. The experiment analysis results show that under the same cutting parameters condition, machined surface roughness in high speed end-milling cutter milling is better than in high speed ball-end milling; within experiment selected cutting parameter range, cutter edge radius is the main influence factor on machined surface roughness in high speed end- milling hardened steel, while the influence on machined surface roughness in high speed ball-end milling hardened steel is not obvious. In end-milling, when edge radius and milling depth are in the same order magnitude or the difference is not obvious, milling depth should be a little bigger than selected cutter edge radius value.

Download Full-text

Effect of Machining Parameters in Milling Aluminum Alloy 7075-T6 under MQL Condition

International Journal of Engineering and Advanced Technology - Regular Issue ◽

10.35940/ijeat.a2231.129219 ◽

2019 ◽

Vol 9 (2) ◽

pp. 109-113

Keyword(s):

Surface Roughness ◽

Aluminum Alloy ◽

Tool Life ◽

Feed Rate ◽

Cutting Tool ◽

Cutting Speed ◽

Machining Parameters ◽

Machined Surface ◽

Machined Surface Roughness ◽

Aluminum Alloy 7075

Minimum quantity lubrication (MQL) is an eco-friendly method, where a small amount of fluid was sprayed to cutting edge in mist form with the aid of the air. The foregoing studies revealed that inappropriate machining parameters without the assistance of the cutting fluid methods became a major challenge in milling aluminum alloy 7075-T6. The paper presents the findings of the experimental work to assess the effect of machining parameters towards cutting tool life and machined surface roughness in milling aluminum alloy 7075-T6 at high cutting speed under MQL condition. An eight-run experiment was designed according to full factorial design based upon two levels of cutting speed (500 m/min, 600 m/min), feed rate (0.12 mm/tooth, 0.15 mm/tooth), and axial depth of cut (1.40 mm, 1.70 mm) and then analyzed employed ANOVA to determine the significant machining parameters. The cutting tool life and machined surface roughness were assigned by the rejection criterion of tool flank wear in the milling operation. The optical microscope and portable surface roughness tester were applied to analyze tool wear and average surface roughness value. Cutting speed and feed rate were significantly contributing to the tool life and surface roughness. The longest tool lifespan of 20.14 minutes and lowest surface roughness value of 0.569 µm were obtained at a speed of 500 and 600 m/min, respectively, with a low combination of the rest of parameter which are 0.12 mm/tooth and 1.40 mm.

Download Full-text

Anticorrosion property enhancement of Al–Li alloy 2A97 by lowering machined surface roughness

Materials and Corrosion ◽

10.1002/maco.202011846 ◽

2020 ◽

Vol 71 (12) ◽

pp. 1980-1988 ◽

Cited By ~ 1

Author(s):

Jintao Niu ◽

Zhanqiang Liu ◽

Guijie Wang ◽

Weimin Huang ◽

Ying Xu

Keyword(s):

Surface Roughness ◽

Anticorrosion Property ◽

Machined Surface ◽

Machined Surface Roughness

Download Full-text

Simulation of Meso-Scale Machining of AISI1045 Based on Multiphase Model

Materials Science Forum ◽

10.4028/www.scientific.net/msf.836-837.374 ◽

2016 ◽

Vol 836-837 ◽

pp. 374-380

Author(s):

Teng Yi Shang ◽

Li Jing Xie ◽

Xiao Lei Chen ◽

Yu Qin ◽

Tie Fu

Keyword(s):

Cutting Force ◽

Cutting Process ◽

Multiphase Model ◽

Tool Edge Radius ◽

Edge Radius ◽

Tool Edge ◽

Cutting Insert ◽

Multiphase Models ◽

Hot Rolled ◽

Meso Scale

In the meso-scale machining, feed rate, grain size and tool edge radius are in the same order of magnitude, and cutting process is often carried out in the grain interior and grain boundary. In this paper the meso-cutting process of hot-rolled AISI1045 steel is studied and its metallographic microstructure is analyzed for the establishment of multiphase models which incorporate the effect of ferrite and pearlite grains. In order to discover the applicability of multiphase models to the simulation of meso-cutting, three contrast simulation models including multiphase model with rounded-edge cutting insert (model I), multiphase model with sharp edge cutting insert (model II) and equivalent homogeneous material model with rounded-edge cutting insert (model III) are built up for the meso-orthogonal cutting processes of hot-rolled AISI1045. By comparison with the experiments in terms of chip morphology, cutting force and specific cutting force, the most suitable model is identified. Then the stress distiribution is analyzed. And it is found that multiphase model with tool edge radius can give a more accurate prediction of the global variables and reveal more about these important local variables distribution.

Download Full-text

Experimental Investigation on Surface Roughness in Precision Cutting Ti6Al4V Alloy Using Diamond Tools

Materials Science Forum ◽

10.4028/www.scientific.net/msf.800-801.576 ◽

2014 ◽

Vol 800-801 ◽

pp. 576-579

Author(s):

Lin Hua Hu ◽

Ming Zhou ◽

Yu Liang Zhang

Keyword(s):

Surface Roughness ◽

Cutting Speed ◽

Polycrystalline Diamond ◽

Cutting Parameters ◽

Limited Range ◽

Nose Radius ◽

Machined Surface ◽

Machined Surface Roughness ◽

Titanium Alloy Ti6al4v ◽

Pcd Tools

In this work, cutting experiments were carried out on titanium alloy Ti6Al4V by using polycrystalline diamond (PCD) tools to investigate the effects of the tool geometries and cutting parameters on machined surface roughness. Experimental results show machined surface roughness decreases with increases in the flank angle, tool nose radius and cutting speed within a limited range respectively, and begins to increase as the factors reaches to certain values respectively. And machined surface roughness decreases with increases in feed rate and cutting depth respectively.

Download Full-text

Experimental Research on Surface Roughness of Ultrasonic Assisted Grinding on 7075 Aluminum Alloy

Materials Science Forum ◽

10.4028/www.scientific.net/msf.1047.62 ◽

2021 ◽

Vol 1047 ◽

pp. 62-67

Author(s):

Shen Wang ◽

Le Tong ◽

Guang Jun Chen ◽

Mao Xun Wang ◽

Bin Dai ◽

...

Keyword(s):

Surface Roughness ◽

Aluminum Alloy ◽

Processing Parameters ◽

7075 Aluminum Alloy ◽

Machined Surface ◽

Ultrasonic Assisted Grinding ◽

Great Performance ◽

Ultrasonic Assisted ◽

Conventional Grinding ◽

Micro Morphology

7075 aluminum alloy is widely used due to its great performance, especially in aerospace area. In this paper, ultrasonic-assisted grinding technology is used to process 7075 aluminum alloy. The data is obtained through experiments, and the surface roughness and morphology of ultrasonic assisted grinding and conventional grinding under different spindle speeds, feed rates, and amplitudes are analyzed. Research has found that the increase in spindle speed and amplitude will improve the quality of the machined surface and reduce the surface roughness by 82.1% and 36%. However, with the increase of feed rate, the surface quality decreased significantly, and the surface roughness increased by 55.6%. The surface micro-morphology of the machined workpiece is observed, and the effects of different processing parameters on the surface micro-morphology are obtained.

Download Full-text

COMPARISON OF PREPARATION METHODS IN TERMS OF TOOL LIFE AND SURFACE ROUGHNESS

MM Science Journal ◽

10.17973/mmsj.2021_10_2021101 ◽

2021 ◽

Vol 2021 (4) ◽

pp. 4836-4840

Author(s):

ROBERT STRAKA ◽

◽

JOZEF PETERKA ◽

TOMAS VOPAT ◽

◽

...

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Cutting Parameters ◽

Turning Process ◽

Machined Surface ◽

Preparation Methods ◽

Machined Surface Roughness ◽

Cutting Inserts ◽

Drag Finishing ◽

Edge Preparation

The article compares two cutting edge preparation methods and their influence on the machined surface roughness of the difficult to cut nickel alloy Inconel 718 and the tool wear of cutting inserts made of cemented carbide. The manufacturing and preparation process of cutting inserts used in the experiment were made by Dormer Pramet. The preparation methods used in the experiment were drag finishing and brushing. Cutting parameters did not change during the whole turning process to maintain the same conditions in each step of the process and were determined based on tests for a semi-finishing operation of the turning process. To obtain durability of 25 to 30 minutes with controlled development of the tool wear the cutting parameters were determined with cooperation with the cutting inserts manufacturer.

Download Full-text

Evaluation of DPI Change Impact on Laser Machined Surface Quality

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.474.369 ◽

2014 ◽

Vol 474 ◽

pp. 369-374

Author(s):

Jana Knedlova ◽

Libuše Sýkorová ◽

Vladimír Pata ◽

Martina Malachová

Keyword(s):

Surface Roughness ◽

Surface Quality ◽

Laser Micromachining ◽

Technological Parameters ◽

Machined Surface ◽

Machined Surface Quality ◽

Machined Surface Roughness ◽

Change Impact

The article focuses on the field of PMMA laser micromachining at change of the technological parameters. The aim was to evaluate machined surface roughness at different setting of DPI definition (number of dots paths on square inch). Commercial CO2laser Mercury L-30 by firm LaserPro, USA was used for experimental machining. Ray of laser could be focused on mark diameter d=185 mm.

Download Full-text