scholarly journals Analysis of cutting forces during in-cut and out-cut milling of EN AC-AlSi10Mg cast aluminum alloy

Mechanik ◽  
2018 ◽  
Vol 91 (10) ◽  
pp. 871-873
Author(s):  
Józef Kuczmaszewski ◽  
Paweł Pieśko ◽  
Magdalena Zawada-Michałowska
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cast Aluminum Alloy ◽  
Cast Aluminum ◽  
Technological Parameters ◽  
High Speed Cutting

The analysis of cutting forces during in-cut and out-cut milling of EN AC-AlSi10Mg cast aluminum alloy was presented. The research included measurement of the components of the total cutting force: Ff, Fp and Fc (Fx, Fy, Fz respectively) and determination of their amplitudes at a constant feed per tooth value and the adopted variable technological parameters, i.e.: depth of cut ap, milling width ae and cutting speed vc. Based on the obtained results, it was found that along with the increase in the depth of cut and the milling width, the values of selected components and their amplitudes increase for both in-cut and out-cut milling. During rise of cutting speed, it was observed that the components of the total cutting force increase to the speed vc = 450 m/min, then their values begin to decrease. This is related to the transition from conventional machining to the range of High Speed Cutting. It is important that higher values of cutting forces were noted in the case of out-cut milling instead of in-cut milling.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

An Experiment-Based Investigation on Characteristic and Model of Milling Forces during End-Milling Aluminum Alloy

2014 ◽  
Vol 494-495 ◽  
pp. 602-605
Author(s):  
Zeng Hui An ◽  
Xiu Li Fu ◽  
Ya Nan Pan ◽  
Ai Jun Tang
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
End Milling ◽  
Influence Factors ◽  
Cutting Speed ◽  
Cutting Depth ◽  
Milling Forces

Cutting forces is one of the important physical phenomena in metal cutting process. It directly affects the surface quality of machining, tool life and cutting stability. The orthogonal experiments of cutting forces and influence factors with indexable and solid end mill were accomplished and the predictive model of milling force was established during high speed end milling 7050-T7451 aluminum alloy. The paper makes research mainly on the influence which the cutting speed, cutting depth and feed have on the cutting force. The experimental results of single factor showed that the cutting forces increase earlier and drop later with the increase of cutting speed, and the cutting speed of inflexion for 7050-T7451 is 1100m/min. As axial cutting depth, radial cutting depth and feed rate increase, the cutting force grows in different degree. The cutting force is particularly sensitive to axial cutting depth and slightly to the radial cutting depth.

Influence of Cutting Parameters on Residual Stresses Induced by Milling in Pressure Die-Cast Aluminum Alloy Components

2000 ◽  
Vol 123 (4) ◽  
pp. 547-551 ◽  
Author(s):  
T. Berruti ◽  
G. Ubertalli
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cast Aluminum Alloy ◽  
Feed Speed ◽  
Cast Aluminum ◽  
X Ray ◽  
Die Cast ◽  
Experimental Apparatus

Residual stress states, induced by milling in a die cast aluminum alloy component, have been determined by means of X-ray diffraction. Samples have been cut from an automotive engine sump, fabricated by pressure die-casting. The X-ray experimental apparatus has been calibrated by detecting stresses on a sample bent under imposed external deformations. Different samples (cut from the sump) have been tested after milling operations with each one characterized by different cutting speed, feed speed and depth of cut in order to evaluate their influence on the final residual stress state. Results have been analyzed taking into account surface morphologies after milling, as revealed by scanning electron microscopy.

Study on Cutting Forces of Mg-6Nd-4Gd-3Y Magnesium Alloy in High-Speed Milling

2011 ◽  
Vol 338 ◽  
pp. 709-713
Author(s):  
Zhen Hua Wang ◽  
Jun Tang Yuan
Keyword(s):  
Magnesium Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Polynomial Regression ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Partial Least Square ◽  
Depth Of Cut ◽  
High Speed Milling

In this paper, 24full factorial design and homogeneous design were applied to the high-speed milling experiments for Mg-6Nd-4Gd-3Y magnesium alloy. According to the experimental results of cutting force, the effect of cutting parameters (cutting speed, feed per tooth, depth of cut, and width of cut) on cutting force was discussed, and the nonlinear polynomial regression models of cutting forces based on the cutting parameters were presented by the partial least-square regression.

Influence on Cutting Forces and Vibration in High Speed Machining Pocket Corner

2011 ◽  
Vol 189-193 ◽  
pp. 3084-3088
Author(s):  
De Wen Tang ◽  
Ru Shu Peng ◽  
Rui Lan Zhao
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Sudden Change ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Poor Quality ◽  
Depth Of Cut ◽  
Processing Efficiency ◽  
Radial Depth

High speed milling hardened mould steel (above HRC50) at pocket corner generates the cutting forces increase and vibration gets fiercely because of the sudden change of cutting direction. It will cause serious wear and possible breakage of cutting tool, and poor quality of parts. Hence, the need to select reasonable cutting parameters and adopt appropriate cutting strategies will help them to achieve their goal. In this paper, the effects cutting parameters including cutting speed, pocket corner angle, feed rate per tooth and radial depth of cut on cutting force and vibration are studied. The results show that sharper pocket corner results in the increase of cutting force and makes vibration strong. Cutting force increase with the increase of cutting speeding, feed per tooth and radial depth of cut. The optimum of cutting speed leads to the decrease of vibration. It is proposed that cutting parameters should be optimized to improve tool life and processing efficiency.

scholarly journals Cutting Force Prediction Models by FEA and RSM When Machining X56 Steel with Single Diamond Grit

Micromachines ◽  
2021 ◽  
Vol 12 (3) ◽  
pp. 326
Author(s):  
Lan Zhang ◽  
Xianbin Sha ◽  
Ming Liu ◽  
Liquan Wang ◽  
Yongyin Pang
Keyword(s):  
Cutting Force ◽  
Coefficient Of Friction ◽  
High Speed ◽  
Prediction Models ◽  
Pipeline Steel ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Diamond Wire Saw

In the field of underwater emergency maintenance, submarine pipeline cutting is generally performed by a diamond wire saw. The process, in essence, involves diamond grits distributed on the surface of the beads cutting X56 pipeline steel bit by bit at high speed. To find the effect of the different parameters (cutting speed, coefficient of friction and depth of cut) on cutting force, the finite element (FEA) method and response surface method (RSM) were adopted to obtain cutting force prediction models. The former was based on 64 simulations; the latter was designed according to DoE (Design of Experiments). Confirmation experiments were executed to validate the regression models. The results indicate that most of the prediction errors were within 10%, which were acceptable in engineering. Based on variance analyses of the RSM models, it could be concluded that the depth of the cut played the most important role in determining the cutting force and coefficient the of friction was less influential. Despite making little direct contribution to the cutting force, the cutting speed is not supposed to be high for reducing the coefficient of friction. The cutting force models are instructive in manufacturing the diamond beads by determining the protrusion height of the diamond grits and the future planning of the cutting parameters.

Globular Crystals in the Center of Roll Cast Aluminum Alloy Strips

2020 ◽  
Vol 1007 ◽  
pp. 34-40
Author(s):  
Toshio Haga ◽  
Maho Tsuchida ◽  
Hirotaka Sakata ◽  
Hisaki Watari ◽  
Shinichi Nishida
Keyword(s):  
Aluminum Alloy ◽  
High Speed ◽  
Strip Casting ◽  
Cast Aluminum Alloy ◽  
Thickness Direction ◽  
Cast Aluminum ◽  
Cooling Slope ◽  
Roll Gap ◽  
Twin Roll ◽  
Center Area

This study investigated the crystallization position and formation mechanism of globular crystals at the center area in the thickness direction of aluminum alloy strips cast by a high-speed twin roll caster. Twin roll casters for single strips and clad strips were used, as well as twin roll casters equipped with a cooling slope. The globular crystals were formed from dividing arms of dendrites of the solidified layer facing the center area at the roll gap. The arms of isolated dendrite also divided. No globular crystals were formed at the interfaces of clad strips with different solidification temperatures because of the temperature gradient at the interface which inhibited division of the dendrite arms. It was demonstrated that globular crystals at the center area of the thickness direction were formed by dendrite-arm-dividing at the roll gap by the strip casting clad strip. Experiments by semisolid-strip casting with the cooling slope showed that globular crystals in the molten metal existed in the solidification layers.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

Investigation of Surface Characteristics and Chip Morphology in High Speed Cutting of Inconel718 Based on SHPB System

2019 ◽  
Author(s):  
Zengqiang Wang ◽  
Zhanfei Zhang ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Kunyang Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Surface Profile ◽  
Chip Morphology ◽  
Depth Of Cut ◽  
Machined Surface ◽  
High Speed Cutting

Abstract High speed cutting (HSC) technology has the characteristics of high material removal rates and high machining precision. In order to study the relationships between chip morphology and machining surface characteristic in high speed cutting of superalloy Inconel718. High-speed orthogonal cutting experiment are carried out by used a high speed cutting device based on split Hopkinson pressure bar (SHPB). The specimen surfaces and collected chips were then detected with optical microscope, scanning electron microscope and three-dimensional surface profile measuring instrument. The results show that within the experimental parameters (cutting speed from 8–16m/s, depth of cut 0.1–0.5mm), the obtained chips are sawtooth chips and periodic micro-ripple appear on the machined surface. With the cutting speed increases, machining surface roughness is decreases from 1.4 to 0.99μm, and the amplitude of periodic ripples also decreases. With the cutting depth increases, the machining surface roughness increases from 0.96 to 5.12μm and surface topography becomes worse. With the increase of cutting speed and depth of cut, the chips are transform from continues sawtooth to sawtooth fragment. By comparing the frequency of surface ripples and sawtooth chips, it is found that they are highly consistent.

Investigation on surface quality of high-speed cutting titanium alloy Ti6Al4V based on Split-Hopkinson pressure bar

2020 ◽  
Vol 234 (10) ◽  
pp. 1293-1301 ◽  
Author(s):  
Zhanfei Zhang ◽  
Zengqiang Wang ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Yifeng Xiong
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Surface Quality ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Hopkinson Pressure Bar ◽  
High Speed Cutting ◽  
Pressure Bar

High-speed cutting technology has the characteristics of high material removal rate and excellent processing quality. To investigate the surface quality of high-speed cutting Ti6Al4V alloy, the orthogonal cutting experiment is the cutting device based on improved Split-Hopkinson pressure bar carried out with a cutting speed of about 7–16 m/s. Surface roughness, residual stress and three-dimensional surface topography are examined to characterize the surface quality. And the chip geometry parameters are measured to analyze the formation mechanism of surface topography. The result shows that cutting force and surface roughness increase rapidly with the increase in depth of cut. In the meantime, the periodic microwaves appeared on the machined surface, and their amplitudes increase with the increase in depth of cut. However, surface roughness, residual stress and microwave amplitude all decrease with the increase in cutting speed. Moreover, it is found that the evolution trend of chip thickness and surface roughness with cutting parameters is very similar. Therefore, it can be inferred that there is a strong relationship between surface topography and chip morphology.

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