scholarly journals Experimental and Numerical Analysis of High-Speed Internally Cooled Milling

CONVERTER ◽  
2021 ◽  
pp. 748-756
Author(s):  
Ningxia Yin Et al.
Keyword(s):  
High Speed ◽  
End Milling ◽  
Double Helix ◽  
Channel Structure ◽  
Dynamics Simulation ◽  
Thermal Dissipation ◽  
Machined Surface ◽  
Milling Tool ◽  
Internally Cooled ◽  
Cooling Technology

Advanced cooling technology is a crucial measure of thermal dissipation for high-speed end-milling. In order to get an appropriate cooling technology and decrease the negative effects of traditional wet cutting, internally cooled cutting has been paid more and more attention. Because of interrupted cutting and uneven force, there was few application and investigation on internally cooled end-milling. In the paper, the effect of the end-milling tool with different internally cooled channel structure has been researched by experiment and theoretical analysis. The experimental results indicate that the end-milling tool with double helix channels carried out best machined surface quality. And the experiment result was also been analyzed and explained by computational fluid dynamics simulation, which provides a basis for the applying of the high-speed internally cooled end-milling tool.

Experimental Investigation of the Effect of the Machine Kinematic Behavior on the Surface Topography and Roughness in High Speed Ball end Milling of the AISI4142 Steel

2021 ◽  
Author(s):  
Sai Lotfi ◽  
Belguith Rami ◽  
Baili Maher ◽  
Desseins Gilles ◽  
Bouzid Wassila
Keyword(s):  
Surface Topography ◽  
High Speed ◽  
End Milling ◽  
Experimental Investigations ◽  
Ball End Milling ◽  
Tool Paths ◽  
Stationary Zone ◽  
Machining Errors ◽  
Kinematic Behavior ◽  
Milling Tool

Abstract The analysis of the surface topography in ball end milling is an objective studied by many researchers, several methods were used and many combinations of cutting conditions and machining errors are considered. In the milling tool paths the trajectories presents a points of changing direction where the tool decelerates before and accelerates after respecting the velocity profiles of the machine. In this paper, we propose experimental investigations of the effect of the kinematic behavior of the machine tool on the surface quality. A poor topography and roughness are remarked on the deceleration and the acceleration zones compared to the stationary zone.

Influence of Inclination Angle on Machined Surface Hardness in High Speed Ball End Milling

2012 ◽  
Vol 500 ◽  
pp. 134-139
Author(s):  
Shi Guo Han ◽  
Jun Zhao ◽  
Xiao Xiao Chen ◽  
Yue En Li ◽  
Qing Yuan Cao ◽  
...  
Keyword(s):  
Inclination Angle ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
High Surface ◽  
Surface Hardness ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Abrasive Resistance ◽  
Feed Direction

In this paper, the effects of the variational combinations of cutter inclination angle in feed direction and the feed per tooth on the machined surface hardness were mainly concerned. The cutting forces transformed from the measured cutting forces in OXYZ and the SEM microstructures of the surface layer were analyzed to explore the generation condition of the hardness. Variations of the surface hardness are not apparent with the increment of feed per tooth with the identical other cutting parameters. Inclination angles in feed direction of approximately ranging from 10° to 15° and from 25° to 30°, which correspond to high surface hardness, are suggested to be applied in cutting process when high abrasive resistance is expected. While values of inclination angle approximately equal to 0° and 45° are prior to be chosen when high shock resistance performance is firstly expected. Optimization of the cutting parameters, which could offer guidance to the machining of sculptured surface concerning cutter inclination angle, was presented.

Experimental investigation of top burr formation in high-speed micro-milling of Ti6Al4V alloy

2019 ◽  
Vol 234 (4) ◽  
pp. 730-738 ◽  
Author(s):  
Mohan Kumar ◽  
Vivek Bajpai
Keyword(s):  
Experimental Investigation ◽  
High Speed ◽  
End Milling ◽  
Cutting Parameters ◽  
Ti6al4v Alloy ◽  
Micro Milling ◽  
Burr Formation ◽  
Machined Surface ◽  
Burr Width ◽  
Super Alloy

Miniaturization with superior quality product of super alloy is the demand of the industry. Ti6Al4V is the demanding super alloy due to its excellent material properties, although this super alloy is known for poor machinability in terms of burr formation, low tool life, and poor surface finish. Therefore, being a popular super alloy, it comes under the difficult-to-cut material. In the current work, burr formation on the machining of Ti6Al4V has been studied. Experimental investigation and characterizations of top burr formation on Ti6Al4V alloy using end milling process were carried out. A scanning electron microscopy identifies the burr formed on the machined surface. A new technique has been introduced to measure the top burr width (i.e. equivalent width) accurately. Equivalent burr width calculated as the ratio of total area of burr generated to the total height. It was observed that equivalent burr width in up milling was increased by 120%, while in down milling, it was decreased by 50% as the speed varies from conventional to high speed. Furthermore, the effects of different cutting parameters and tool parameters on top burr formation have been analyzed to establish correlation among them.

Surface Topography and Roughness Simulations for 5-Axis Ball-End Milling

2009 ◽  
Vol 69-70 ◽  
pp. 471-475 ◽  
Author(s):  
Shi Guo Han ◽  
Jun Zhao ◽  
Xiao Feng Zhang
Keyword(s):  
Surface Topography ◽  
Surface Quality ◽  
High Speed ◽  
End Milling ◽  
Analytical Form ◽  
Influential Factors ◽  
Sculptured Surfaces ◽  
Machined Surface ◽  
Ball End Milling ◽  
Five Axis

In five-axis high speed milling of freeform surface with ball-end cutters, unwanted machining results are usually introduced by some error effects. Hence precise modeling and simulation of milled sculptured surfaces topography and roughness is the key to obtain optimal process parameters, satisfactory surface quality and high machining efficiency. In this paper, a predictive model for sculptured surface topography and roughness of ball-end milling is developed. Firstly, a mathematical model including both the relative motion of the cutter-workpiece couple and some influential factors on machined surface quality such as the tool runout, tool deflection and tool wear is proposed, and subsequently the analytical form of the tool swept envelope is derived by means of homogeneous coordinate transformation. Then the minimal z-values of the corresponding points lied in discrete cutting edges model and Z-map workpiece model are used to update the workpiece surface topography and to calculate 3D surface roughness. Finally, the simulation algorithm is realized with Matlab software. A series of machining tests on 3Cr2MoNi steel are conducted to validate the model, and the machined surface topography is found in good accordance with the simulation result.

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

2010 ◽  
Vol 136 ◽  
pp. 86-90 ◽  
Author(s):  
Wei Zhang ◽  
Min Li Zheng ◽  
Ming Ming Cheng ◽  
Quan Wan
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.

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

2013 ◽  
Vol 670 ◽  
pp. 70-75 ◽  
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.

scholarly journals Micro-End-Milling with Small Diameter Left Hand Helical Tool for High Quality Vertical Wall Machining

2019 ◽  
Vol 13 (5) ◽  
pp. 639-647
Author(s):  
Keiji Ogawa ◽  
Takumi Imada ◽  
Haruki Kino ◽  
Heisaburo Nakagawa ◽  
Hitomi Kojima ◽  
...  
Keyword(s):  
High Speed ◽  
End Milling ◽  
Vertical Wall ◽  
Small Diameter ◽  
Cutting Edge ◽  
End Mill ◽  
High Quality ◽  
Machined Surface ◽  
Left Hand ◽  
Micro End Milling

The demand for micro-end-milling for products in fields such as the medical, optical, and electronics industry is increasing. However, when machining with a small diameter end-mill (micro-end-mill) with diameters such as 0.5 mm, the rigidity of the tool itself is low; hence, the cutting conditions must be set to low values to achieve stable machining. Therefore, we examined various cutting phenomena that occur during actual machining processes to achieve high machining accuracy, high finished-surface quality, and long tool life. Some studies on micromachining achieved high accuracy, high-grade machining by considering the cutting phenomena. In previous papers, we dealt with the side-cutting phenomena in micro-end-milling of hardened die steels using a high-speed air-turbine spindle with rolling bearing. Cutting experiments were carried out by measuring the cutting force and flank wear of a cutting tool to investigate the difference in cutting phenomena caused by cutting direction in high-speed micro-end-milling. Observation of the machined surface and measurement of the profile of the cutting edge and machined surface were demonstrated. It was revealed that machining quality in high-speed up-cut milling was better than that in down-cut milling. Shoulder cutting, in which both peripheral and bottom cutting edges act simultaneously on the workpiece, was also investigated. A novel small diameter end-mill with left-hand helical tool with right-hand cut was developed to avoid damaging the cutting edge in the initial cutting stage. In the present study, high-quality shoulder cutting of a vertical wall using the new tool was proposed and demonstrated.

Cutting Thickness of High Speed Ball-End Milling Hardened Steel

2012 ◽  
Vol 426 ◽  
pp. 24-27
Author(s):  
Shu Cai Yang ◽  
Bin Jiang ◽  
H.Y. Li ◽  
M.L. Zheng ◽  
S.J. Wang
Keyword(s):  
High Speed ◽  
End Milling ◽  
Chip Thickness ◽  
Surface Damage ◽  
Transformation Process ◽  
Hardened Steel ◽  
Machined Surface ◽  
Element Analysis ◽  
Ball End Milling ◽  
Adiabatic Shearing

In order to solve the problem of machined surface damage and machining efficiency decline that caused by the decrease of effective cutting thickness in high speed ball-end milling hardened steel, using high speed cutting adiabatic shearing model, analyzed the adiabatic shearing deformation on hardened steel, and proposed the criterion of chip separating position. Analyzed the force in the transformation process from cutting to plowing, the influence of cutter deformation on cutting thickness was studied, and established the minimum cutting thickness model. Having done finite element analysis of cutter and experiment of high speed milling hardened steel, the validity of the minimum cutting thickness model was proved. The results show that cutting thickness changes from small to large, and then from large to small under the influence of cutting trajectory and tool edge radius. The deformation of cutter leads to the increase of the minimum cutting thickness, and further enhances chip thickness thinning effect. High feed can compensate cutting thickness thinning and the minimum cutting thickness model provides an effective way to restrain the damage of machined surface and cutter caused by cutter plowing.

Effect of High Speed Dry End Milling on Surface Roughness and Cutting Forces of Ti-6Al-4V ELI

2014 ◽  
Vol 493 ◽  
pp. 546-551 ◽  
Author(s):  
Safian Sharif ◽  
Habib Safari ◽  
Sudin Izman ◽  
Denni Kurniawan
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Machined Surface ◽  
Milled Surface ◽  
Cemented Carbide Tools ◽  
Cutting Speeds

The surface quality generated when high speed dry end milling (HSDEM) Ti-6Al-4V-ELI titanium alloy with coated and uncoated carbide tools were investigated. Evaluation was conducted using TiAlN+TiN coated and uncoated cemented carbide tools under different high cutting speeds and feed rates conditions. Surface roughness and cutting forces were measured when using new tools. The milled surface quality and corresponding alteration were characterized through electron microscopy. Within the investigated conditions high quality surface finish was obtained on the machined surface. Increasing cutting speed from 200 to 300 m/min during the process improved the surface finished particularly under lower feed rates. In term of generated surface quality, uncoated H25 grade carbide tools out performed coated F40M grade specifically at the higher cutting conditions. The main damages observed after HSDEM on the surface for all machining conditions contain redeposited materials, feed marks, and tool edge marks. Under both tested feed rates the resultant cutting force decreased by increasing the cutting speeds and uncoated carbide tools provide the lower cutting forces compared to coated types.

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