scholarly journals Study on Design, Manufacture and Cutting Performance of Circular-arc Milling Cutters for Machining Titanium Alloy

2021 ◽  
Author(s):  
Tao Chen ◽  
Liu Gang ◽  
Li Rui ◽  
Lu Yujiang ◽  
Wang Guangyue
Keyword(s):  
Titanium Alloy ◽  
Surface Quality ◽  
End Milling ◽  
Geometric Model ◽  
Cutting Edge ◽  
Grinding Wheel ◽  
Side Milling ◽  
Edge Structure ◽  
Circular Arc ◽  
Milling Forces

Abstract Titanium alloy is widely used for manufacturing structural parts of high-end equipment due to its excellent mechanical properties, despite difficulty in being machined. Nowadays, titanium alloy parts are mostly machined by ball-end milling cutters (BEMC), but the cutting edge structure of the BEMC limits the improvement in machining efficiency and surface quality of the parts. In this paper, a circular-arc milling cutter (CAMC) with large-curvature cutting edge was proposed; the differential geometry method was used for establishing the geometric model for the contour surface of the CAMC and the mathematical model for the spiral cutting edge line; the conversion matrix between grinding wheel and workpiece coordinates was introduced to derive the equation of grinding wheel trajectory when the rake face of the CAMC was ground; the self-designed CAMC was ground and tested in accuracy. The comparative research was conducted experimentally on the side milling of titanium alloy TC4 with the CAMC and BEMC, and consequently the variation laws of milling forces, wear morphology and machined surface quality were obtained about the two types of milling cutters. The results indicated that the CAMC can effectively reduce the main milling force and keep the milling process stable. Moreover, the CAMC was worn slower and produced better surface quality than the BEMC.

scholarly journals Research on Cutting Performance in High-speed Milling of TC11 Titanium Alloy Using Self-propelled Rotary Milling Cutters

2021 ◽  
Author(s):  
Yujiang Lu ◽  
Tao Chen
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Quality ◽  
Wear Mechanism ◽  
High Speed ◽  
Cutting Edge ◽  
Machining Process ◽  
High Speed Milling ◽  
Tc11 Titanium Alloy ◽  
Milling Forces

Abstract Titanium alloy materials, with excellent chemical and physical properties, are widely applied to the manufacture of key components in the aerospace industry. Nevertheless, its hard-to-machine characteristic causes various problems in the machining process, such as severe tool wear, difficulty to ensure good surface quality, etc. To achieve high efficiency and quality of machining titanium alloy materials, this paper conducted an experimental research on the high-speed milling of TC11 titanium alloy with self-propelled rotary milling cutters. In the work, the wear mechanism of self-propelled rotary milling cutters was explored, the influence of milling velocity was analyzed on the cutting process, and the variation laws were obtained of milling forces, chip morphology and machined surface quality with the milling length. The results showed that in the early and middle stages of milling, the insert coating peeled off evenly under the joint action of abrasive and adhesive wear mechanisms. As the milling length increased, the dense notches occurred on the cutting edge of the cutter, the wear mechanism converted gradually into fatigue wear, and furthermore coating started peeling off the cutting edge with the occurrence of thermal fatigue cracks on the insert. As the milling length was further extended, the milling forces tended to intensify, the chip deformation worsened, and the obvious cracks occurred at the bottom of chips. Moreover, the rise in milling velocity reduced the tool wear resistance, increased obviously the milling forces and the surface roughness.

A HIGHER FIDELITY MODELING OF THE CUTTING EDGE OF BALL-END MILLING TOOL

2011 ◽  
Vol 10 (01) ◽  
pp. 101-108 ◽  
Author(s):  
XIULIN SUI ◽  
IMRE HORVATH ◽  
JIATAI ZHANG ◽  
PING ZHANG
Keyword(s):  
End Milling ◽  
Milling Process ◽  
Cutting Edge ◽  
Ball End Milling ◽  
Machining Conditions ◽  
Milling Tool ◽  
Efficient Planning ◽  
Pilot Implementation ◽  
Physical Changes ◽  
Milling Forces

Ball-end milling tools have been widely used in machining of complex freeform surfaces. The precision and efficiency of ball-end milling process can be improved by an accurate modeling of the tools, the tools' paths and the machining conditions. However, only rough geometric models have been applied so far, which do not consider the machining conditions and the physical changes. To achieve the best results, an accurate modeling of the cutting edge and the physical behavior of the entire cutter is needed. This paper proposes an articulated model that enumerates both the geometric characteristics and the physical effects acting on the cutting edge-segment of a ball-end milling cutter. The model considers the deformations caused by the milling forces, vibration, spindle eccentricity, together with thermal deformation and wear of the cutter. The mathematical description of the behavior has been transferred into a computational model. The pilot implementation has been tested in a practical application. The first findings show that the proposed theoretical model and implementation provide sufficiently precise information about the behavior of the cutter in virtual simulations; hence it can be the basis of a fully fledged and more efficient planning of milling processes.

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

2014 ◽  
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.

Effect of Tool Wear on Surface Qualities in Milling of TC4

2016 ◽  
Vol 836-837 ◽  
pp. 132-138 ◽  
Author(s):  
Shu Cai Yang ◽  
Xiao Yang Cui ◽  
Yu Hua Zhang ◽  
Zhi Wei Wang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Quality ◽  
End Milling ◽  
Great Influence ◽  
Chip Morphology ◽  
Milling Process ◽  
Serrated Chip ◽  
Quality Surface

Tool wear is easy occurred in titanium alloy milling process which will affect the surface quality. Surface roughness and surface morphology as an important index to describe and evaluate the surface quality has a great influence on service performance. Therefore, the study on the effect of tool wear on surface qualities is important to improve the surface integrity of titanium alloy parts. Cutting radius of ball-end milling cutter is solved to analyze the effect of tool wear on the cutting radius. The tool wear and the surface qualities of TC4 are achieved through wear experiment. And then the influence law of tool wear on surface qualities and chip morphology are analyzed. The results show that surface roughness value decrease firstly and then increases and that chip morphology with flank wear increase from the unit chip to the serrated chip.

Grinding Process of Ball End Milling Cutter Flank

2018 ◽  
Vol 764 ◽  
pp. 383-390 ◽  
Author(s):  
Quan Qi Xin ◽  
Tai Yong Wang ◽  
Zhi Qiang Yu ◽  
Hong Yan Hu
Keyword(s):  
Mathematical Model ◽  
End Milling ◽  
Cutting Edge ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Position And Orientation ◽  
The Mathematical Model

In this paper, the mathematical model of "S" - shaped cutting-edge curve is optimized, and the position and orientation of the grinding wheel of the first and second flank of the ball end milling cutter are calculated, The correctness of the algorithm is verified by VERICUT simulation.

scholarly journals Predictive modelling of cutting forces in end milling of titanium alloy Ti6Al4V

2016 ◽  
Vol 232 (9) ◽  
pp. 1523-1534 ◽  
Author(s):  
Yun Chen ◽  
Huaizhong Li ◽  
Jun Wang
Keyword(s):  
Titanium Alloy ◽  
Predictive Model ◽  
End Milling ◽  
Mechanistic Model ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Material Strength ◽  
Force Model ◽  
Serrated Chip ◽  
Titanium Alloy Ti6al4v

A cutting force model, based on a predictive model for orthogonal cutting, is developed for force predictions in end milling of titanium alloy Ti6Al4V. The model assumes a semi-stationary process for the serrated chip formation. The Johnson–Cook material model that couples strain hardening, strain rate sensitivity and thermal softening effects is applied to represent the material strength. A thermal model considering the tool thermal properties is integrated to account for the high temperature rise due to the low thermal conductivity of Ti6Al4V. To extend the predictive model to milling, the end mill is discretised into several axial slices, and an equivalent cutting edge is used to include the end cutting edge effect caused by the first axial slice. The model is assessed by comparing its prediction with the experimental results and a mechanistic model for verification. The results show that the proposed model outperforms the mechanistic model with higher accuracy in force prediction.

The Grinding and Test of Annular Milling Cutter with Double-Circular-Arc

2016 ◽  
Vol 836-837 ◽  
pp. 205-211
Author(s):  
Tao Chen ◽  
Xian Chuang Li ◽  
Chang Hong Wang ◽  
Guang Miao ◽  
Yan Yan Wang
Keyword(s):  
Cutting Edge ◽  
Smooth Transition ◽  
Grinding Wheel ◽  
Milling Cutter ◽  
Circular Arc ◽  
Grinding Method ◽  
Result Show ◽  
Standard Cutter ◽  
Five Axis ◽  
Deformation Error

For the problem of the non standard cutter shape cutting edge not smooth transition connection and flank face of cutting tool grinding precision difference, the influence of wheel deformation is analyzed to different grinding linear speed, and the grinding wheel deformation error compensation grinding method is studied in this work. The grinding of annular milling cutter with double-circular-arc is processed in five axis CNC tool grinder. Finally the machining precision of annular milling cutter with double-circular-arc is tested by the tool test center, the result show that the wheel grinding method based on compensation of grinding can realize smooth transition in different parts of cutting edge belt of annular milling cutter with double-circular-arc and flank grinding precision is ensured.

scholarly journals Study on mechanical properties of titanium alloy with micro-texture ball-end milling cutter under different cutting edges

2020 ◽  
Vol 12 (7) ◽  
pp. 168781402090842
Author(s):  
Shucai Yang ◽  
Shuai Su ◽  
Xianliang Wang ◽  
Wei Ren
Keyword(s):  
Titanium Alloy ◽  
End Milling ◽  
Cutting Edge ◽  
Milling Force ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Edge Geometry ◽  
Optimum Parameters ◽  
Cutting Surface ◽  
Texture Parameters

When precision cutting titanium alloy, the cutting part of cutting tool is mainly concentrated in the cutting edge area, so there is a strong emphasis upon the cutting edge’s geometric parameters. Studies have found that putting a micro-texture on the cutting surface can reduce the cutting force. This article looks at the milling force involved in cutting titanium alloy with a micro-textured ball-end milling cutter with different shaped cutting edges. First, a milling model relating to different cutting edges is established based on the traditional model of milling force. Then, the effects of different cutting edge geometry parameters and micro-texture parameters on milling force are simulated and tested using a finite element method. With milling force serving as the evaluation index, the optimum micro-texture parameters for a blunt circular cutting edge are a micro-pit diameter of 40 μm, a distance between micro-pits of 175 μm, a distance from the cutting edge of 110 μm, and a blunt circle radius of 60 μm. For a negative chamfer edge, the optimum parameters were a micro-pit diameter of 50 μm, a distance between micro-pits of 175 μm, a distance from the cutting edge of 120 μm, an edge width of 200 μm, and an edge angle of 10°.

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