Precision Machining of Sintered Zirconia Ceramics by High-Speed Milling

2017 ◽  
Vol 11 (6) ◽  
pp. 862-868 ◽  
Author(s):  
Yusuke Ito ◽  
◽  
Naohiko Sugita ◽  
Tatsuya Fujii ◽  
Toru Kizaki ◽  
...  
Keyword(s):  
High Speed ◽  
Bending Strength ◽  
Cutting Speed ◽  
High Hardness ◽  
Milling Process ◽  
Precision Machining ◽  
Zirconia Ceramics ◽  
High Speed Milling ◽  
High Cutting Speed ◽  
Dental Prostheses

Precision machining of sintered zirconia ceramics is expected for various applications such as dental prostheses or artificial femoral heads. However, machining of zirconia is a major challenge because of its high hardness. We have found that the bending strength and fracture toughness of this material decrease with an increase in temperature. To use this characteristic, we propose a high-speed milling process with a cutting speed of more than 500 m/min because high-cutting speed can generate a large amount of heat during cutting. According to the results of trials, precision machining of the surface was possible with a cutting speed of 670 m/min. Moreover, the amount of flank wear was decreased by the high-speed milling. These results confirmed the possibility of precision cutting of sintered zirconia ceramics.

scholarly journals Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

2021 ◽  
pp. 71-84
Author(s):  
Nhu-Tung Nguyen ◽  
Dung Hoang Tien ◽  
Nguyen Tien Tung ◽  
Nguyen Duc Luan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
High Speed Milling

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

Simulation on Cutting Temperature during High-Speed Milling Aluminum Alloy 7055

2013 ◽  
Vol 328 ◽  
pp. 486-490 ◽  
Author(s):  
Liang Tan ◽  
Chang Feng Yao ◽  
Wei Zuo ◽  
Dao Xia Wu
Keyword(s):  
Aluminum Alloy ◽  
Theoretical Basis ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Element Model ◽  
Milling Process ◽  
High Speed Milling ◽  
Milling Parameters

To optimize the parameters of high-speed milling of aluminum alloy 7055 and provide a theoretical basis for cutting temperature control, a finite element model of high-speed milling process of aluminum alloy 7055 was developed with AdvantEdge. Based on these models, the effect of milling parameters on cutting temperature is investigated by single factor experiments. And the temperature distribution of workpiece and cutting tool is predicted. The results show that the highest temperature occurs at close to the tool tip in the rack face, the temperature increases with an increase in cutting speed and feed per tooth, while other parameters have a less significant effect on cutting temperature.

Measurement and Analysis of Cutting Force and Optimization of Cutting Parameters by High Speed Milling

2011 ◽  
Vol 141 ◽  
pp. 344-349
Author(s):  
Hu Zeng Li ◽  
Yi Wang ◽  
Nai Xiong Zhu ◽  
Rao Bo Hu ◽  
Chong Zhang ◽  
...  
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
High Speed Milling ◽  
High Cutting Speed ◽  
High Feed ◽  
Optimization Of Cutting Parameters

The measurement method and apparatus of cutting force by high speed milling is introduced. The high speed milling force of wrought aluminum alloy is measured and analyzed through separately examining the influences of various factors, such as cutting speed, cutting depth, milling width, feed per cutting tooth, down or up milling, cooling and lubricating. The results match with outcomes from other’s tests and the theory of metal cutting, and are close to the calculated force values, so that the test can be regarded as positive. It is pointed out that high cutting speed, little cutting depth, properly great working engagement and feed per tooth, high feed rate, down milling and efficient cooling and lubricating should be used to reduce cutting force and deformation, to improve milling accuracy and efficiency, which can be helpful to the spread applications of High Speed Machining.

Investigation of Cutting Force and Tool Wear in High Speed Milling of GH4169 Using Ceramic Tools

2014 ◽  
Vol 800-801 ◽  
pp. 42-47 ◽  
Author(s):  
Peng Fei Sun ◽  
Jian Fei Sun ◽  
Wu Yi Chen ◽  
Xun Shen
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Feed Speed ◽  
High Speed Milling ◽  
Ceramic Tools ◽  
High Cutting Speed

Experiments were carried out to investigate the cutting force and tool wear behavior of Sialon ceramic tools in high speed milling of GH4169 under different cutting parameters. The cutting speed exhibited the most significant influence on the cutting force. The cutting force decreased firstly then increased with the increasing of cutting speed. And the effect of feed speed and cutting depth on cutting force were also discussed. The worn surfaces of tool were examined and the elements on the tool surfaces were analyzed by employing scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS), respectively. The analysis results of the SEM and EDS showed that the dominant wear pattern were rake face flaking and notching at the low cutting speed while flank wear was the main wear type at the high cutting speed of 1037m/min.

Experimental Research on Cutting Temperature of AISI 1045 in High Speed Milling Process

2014 ◽  
Vol 893 ◽  
pp. 621-624
Author(s):  
Yong Feng ◽  
Mu Lan Wang ◽  
Bao Sheng Wang ◽  
Jun Ming Hou
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Experimental System ◽  
Milling Process ◽  
Thermal Imager ◽  
High Speed Milling ◽  
High Speed Cutting ◽  
Aisi 1045

The aim of this paper is to investigate the time dependence distribution of workpiece cutting temperature in milling process. An experimental system used to achieve a measurement of cutting temperature in high speed milling is designed by use of the thermocouple and infrared thermal imager. The general regularity of temperature distribution is concluded, and the influence of the process variables such as cutting speed, cutting depth, etc. on the temperature distribution was investigated in detail. All the experiment results can be effective used to develop a new non-contact soft-sensing method for high speed cutting temperature prediction.

Influence of Cutting Speed on Cutting Force in High-Speed Milling

2010 ◽  
Vol 139-141 ◽  
pp. 835-838 ◽  
Author(s):  
Zhen Yu Zhao ◽  
Yong Shan Xiao ◽  
Yong Qi Zhu ◽  
Bai Liu
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
High Surface ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Milling Process ◽  
High Speed Milling ◽  
Overhang Length ◽  
Experimental Researches ◽  
Very High

High Speed Milling (HSM) is well known as an innovative key technology for modern machining. HSM can obtain very high surface qualities, subsequent manually finishing operations can be eliminated in many cases totally or at least partially. Theoretical and experimental researches have proven that the cutting force in a high speed milling process has significant influences both on surface roughness and deflection of the cutting tool. In this paper, mould steel for high speed milling experiments by multi-factor test on the high speed milling machine tools. By studying the relation of overhang length, cutting speed and cutting force of cutting parameters, the cutting force tested is analyzed in high speed milling. When mold steel is cut at high speed, the influence of cutting speed on cutting force is studied, which has a guidance in the actual production.

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%.

Mechanism of Variable Helix Tools in Suppressing Chatter Using Process Damping for Machining Titanium Alloys at Low Cutting Speed

2013 ◽  
Vol 773-774 ◽  
pp. 370-376
Author(s):  
Muhammad Adib Shaharun ◽  
Ahmad Razlan Yusoff ◽  
Mohammad S. Reza
Keyword(s):  
Titanium Alloy ◽  
Cutting Speed ◽  
Milling Process ◽  
Cutting Process ◽  
Chatter Vibration ◽  
Process Damping ◽  
High Cutting Speed ◽  
Titanium Machining ◽  
Different Types ◽  
Variable Helix

Titanium is difficult-to-cut materials due to its poor machinability and thermal conductivity when machining at high cutting speed. To overcome this machining titanium alloy problem, this study in interaction between machining structural system and the cutting process are very important. One of the main problems in the cutting process is chatter vibration. Due to chatter problem, the mechanism to suppress chatter named, process damping is a useful method can be manipulated to improve the limited productivity of titanium machining at low speed machining in milling process. In the present study, experiment are conducted to evaluate and study the process damping mechanism in milling using different types of variable tools geometries. These tools are variable he-lix/uniform pitch, variable pitch/uniform helix and variable helix and pitch and uniform helix/pitch. The result showed that the variable helix and pitch tools is very significantly improve process damping performance in machining titanium alloy compare to traditional of regular tools and other irregular tools.

Effects of Cutting Parameters on Residual Stresses in High-Speed Milling of Ti-17

2013 ◽  
Vol 834-836 ◽  
pp. 861-865 ◽  
Author(s):  
Yong Shou Liang ◽  
Jun Xue Ren ◽  
Yuan Feng Luo ◽  
Ding Hua Zhang
Keyword(s):  
Experimental Study ◽  
Residual Stresses ◽  
High Speed ◽  
Experimental Parameter ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Single Factor ◽  
Cutting Depth ◽  
High Speed Milling ◽  
Parameter Ranges

An experimental study was conducted to determine cutting parameters of high-speed milling of Ti-17 according to their effects on residual stresses. First, three groups of single factor experiments were carried out to reveal the effects of cutting parameters on residual stresses. Then sensitivity models were established to evaluate the influence degrees of cutting parameters on residual stresses. After that, three criteria were proposed to determine cutting parameters from experimental parameter ranges. In the experiments, the cutting parameter ranges are recommended as [371.8, 406.8] m/min, [0.363, 0.412] mm and [0, 0.018] mm/z for cutting speed, cutting depth and feed per tooth, respectively.

Discrete Element Simulation of the Stress Wave in High Speed Milling

2017 ◽  
Author(s):  
Yifei Jiang ◽  
Jun Zhang ◽  
Yong He ◽  
Hongguang Liu ◽  
Afaque Rafique Memon ◽  
...  
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Discrete Element ◽  
Rake Angle ◽  
Stress Waves ◽  
High Speed Milling ◽  
Element Simulation ◽  
Chip Size ◽  
Distribution Of Stress

As cutting tool penetrates into workpiece, stress waves is induced and propagates in the workpiece. This paper aims to propose a two-dimensional discrete element method to analyze the stress waves effects during high speed milling. The dependence of the stress waves propagation characteristics on rake angle and cutting speed was studied. The simulation results show that the energy distribution of stress waves is more concentrated near the tool tip as the rake angle or the cutting speed increases. In addition, the density of initial cracks in the workpiece near the cutting tool increases when the cutting speed is higher. The high speed milling experiments indicate that the chip size decreases as the cutting speed increases, which is just qualitatively consistent with the simulation.

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