scholarly journals Velocity Effect Sensitivity Analysis of Ball-end Milling Ti-6Al-4V

2021 ◽  
Author(s):  
Anshan Zhang ◽  
Xianli Liu ◽  
Caixu Yue ◽  
Rongyi Li ◽  
Steven Y. Liang ◽  
...  
Keyword(s):  
Surface Quality ◽  
End Milling ◽  
Cutting Speed ◽  
Surface Damage ◽  
Three Dimensions ◽  
Optimal Range ◽  
Machined Surface ◽  
High Position ◽  
Feed Direction ◽  
Velocity Effect

Abstract Ball-end cutters are widely used in industries of dies, molds, and aerospace, which have the problem of poor machined surface quality due to the low cutting speed near the tool-tip. With the increase in the complexity of parts, it will become more and more difficult to avoid the tool-tip participating in the cutting. In this paper, the velocity effect sensitivity of ball-end cutter is analyzed, and several key positions, including the intersection points of the CWE boundaries, are selected to describe the cutting speed in three dimensions. The relationships between the cutting speed of the critical points and important variables such as: machining inclination angle and the feed direction were investigated. The optimal range of feed direction is obtained when the tool-tip engages in the contact circle. The core aim of the feed direction selection is to make the tool engagement area in a high position by changing the feed direction, to avoid surface damage caused by ploughing and improve the quality of the machined surface. Finally, an experimental study was carried out, and the results corroborate the effectiveness of the selection method. In the experiment, it was also found that cutting-out from the cutter contact position can improve the surface quality in the directions of non-optimal range, and the milling force and chips shape will vary with the change of the feed direction.

Experimental Research of Effective Cutting Speed Influence on Surface Roughness in Ball End Milling of C45 Material with Hardness 34 HRC

2014 ◽  
Vol 657 ◽  
pp. 53-57 ◽  
Author(s):  
Sándor Ravai Nagy ◽  
Ioan Paşca ◽  
Mircea Lobonțiu ◽  
Mihai Banica
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Experimental Research ◽  
Inclination Angle ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Speed ◽  
Cnc Machine Tools ◽  
Machined Surface ◽  
Ball End Milling

Machining of Complex Concave or Convex Surfaces Requires the Use of Ball End Milling Cutters. Obtaining the Expected Surface Quality Compete Various Technological Factors which should be Taken into Account. Following the Machining of the Surface with Different Inclination Angles between the Cutting Tool Axes and the Machined Surface, Significant Changes of the Surface Roughness have been Observed. Based on the Tests Performed, we can Determine the Range of the Tool Inclination Angle, which is the Best for the Surface Quality. we have also Made a Correlation between the Cutting Speeds, Inclination Angle of the Cutting Tool Toward the Machined Surface for an Obtained Surface Quality. the Presented Results are Based on Experimental Research in Industrial Conditions by Using CNC Machine Tools with 5 Axes. the Tests have been Performed on the C45 Material, Heat Treated to 34HRC.

scholarly journals Study on the Formation Mechanism of Surface Adhered Damage in Ball-End Milling Ti6Al4V

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7143
Author(s):  
Anshan Zhang ◽  
Caixu Yue ◽  
Xianli Liu ◽  
Steven Y. Liang
Keyword(s):  
Formation Mechanism ◽  
Complex Geometry ◽  
End Milling ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Milling Process ◽  
Cutting Edge ◽  
Machined Surface ◽  
Surface Machining ◽  
Feed Direction

Ball-end cutters are widely used for machining the parts of Ti-6Al-4V, which have the problem of poor machined surface quality due to the low cutting speed near the tool tip. In this paper, through the experiments of inclined surface machining in different feed directions, it is found that the surface adhered damages will form on the machined surface under certain tool postures. It is determined that the formation of surface adhered damage is related to the material adhesion near the cutting edge and the cutting-into/out position within the tool per-rotation cycle. In order to analyze the cutting-into/out process more clearly under different tool postures, the projection models of the cutting edge and the cutter workpiece engagement on the contact plane are established; thus, the complex geometry problem of space is transformed into that of plane. Combined with the case of cutting-into/out, chip morphology, and surface morphology, the formation mechanism of surface adhered damage is analyzed. The analysis results show that the adhered damage can increase the height parameters Sku, Sz, Sp, and Sv of surface topographies. Sz, Sp, and Sv of the normal machined surface without damage (Sku ≈ 3) are about 4–6, 2–3, and 2–3 μm, while Sz, Sp, and Sv with adhered damage (Sku > 3) can reach about 8–20, 4–14, and 3–6 μm in down-milling and 10–25, 7–18, and 3–7 μm in up-milling. The feed direction should be selected along the upper left (Q2: β∈[0°, 90°]) or lower left (Q3: β∈[90°, 180°]) to avoid surface adhered damage in the down-milling process. For up-milling, the feed direction should be selected along the upper right (Q1: β∈(−90°, 0°]) or upper left (Q2: β∈[0°, 90°)).

scholarly journals Effect of Different Cooling Strategies on Surface Quality and Power Consumption in Finishing End Milling of Stainless Steel 316

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 903
Author(s):  
Adel T. Abbas ◽  
Saqib Anwar ◽  
Elshaimaa Abdelnasser ◽  
Monis Luqman ◽  
Jaber E. Abu Qudeiri ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Surface Quality ◽  
Process Parameters ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Machined Surface ◽  
Cooling Strategies ◽  
Dry Conditions

In this paper, an experimental investigation into the machinability of AISI 316 alloy during finishing end milling operation under different cooling conditions and with varying process parameters is presented. Three environmental-friendly cooling strategies were utilized, namely, dry, minimal quantity lubrication (MQL) and MQL with nanoparticles (Al2O3), and the variable process parameters were cutting speed and feed rate. Power consumption and surface quality were utilized as the machining responses to characterize the process performance. Surface quality was examined by evaluating the final surface roughness and surface integrity of the machined surface. The results revealed a reduction in power consumption when MQL and MQL + Al2O3 strategies were applied compared to the dry case by averages of 4.7% and 8.6%, respectively. Besides, a considerable reduction in the surface roughness was noticed with average values of 40% and 44% for MQL and MQL + Al2O3 strategies, respectively, when compared to the dry condition. At the same time, the reduction in generated surface roughness obtained by using MQL + Al2O3 condition was marginal (5.9%) compared with using MQL condition. Moreover, the results showed that the improvement obtained in the surface quality when using MQL and MQL + Al2O3 coolants increased at higher cutting speed and feed rate, and thus, higher productivity can be achieved without deteriorating final surface quality, compared to dry conditions. From scanning electron microscope (SEM) analysis, debris, furrows, plastic deformation irregular friction marks, and bores were found in the surface texture when machining under dry conditions. A slight smoother surface with a nano-polishing effect was found in the case of MQL + Al2O3 compared to the MQL and dry cooling strategies. This proves the effectiveness of lubricant with nanoparticles in reducing the friction and thermal damages on the machined surface as the friction marks were still observed when machining with MQL comparable with the case of MQL + Al2O3.

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.

scholarly journals Influence of Chatter of VMC Arising During End Milling Operation and Cutting Conditions on Quality of Machined Surface

1970 ◽  
Vol 2 (1) ◽  
Author(s):  
A.K.M.N. Amin, M.A. Rizal, and M. Razman
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Metal Removal ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
End Mill ◽  
Machined Surface ◽  
Operating Cycle ◽  
Wide Range

Machine tool chatter is a dynamic instability of the cutting process. Chatter results in poor part surface finish, damaged cutting tool, and an irritating and unacceptable noise. Exten¬sive research has been undertaken to study the mechanisms of chatter formation. Efforts have been also made to prevent the occurrence of chatter vibration. Even though some progress have been made, fundamental studies on the mechanics of metal cutting are necessary to achieve chatter free operation of CNC machine tools to maintain their smooth operating cycle. The same is also true for Vertical Machining Centres (VMC), which operate at high cutting speeds and are capable of offering high metal removal rates. The present work deals with the effect of work materials, cutting conditions and diameter of end mill cutters on the frequency-amplitude characteristics of chatter and on machined surface roughness. Vibration data were recorded using an experimental rig consisting of KISTLER 3-component dynamometer model 9257B, amplifier, scope meters and a PC.  Three different types of vibrations were observed. The first type was a low frequency vibration, associated with the interrupted nature of end mill operation. The second type of vibration was associated with the instability of the chip formation process and the third type was due to chatter. The frequency of the last type remained practically unchanged over a wide range of cutting speed.  It was further observed that chip-tool contact processes had considerable effect on the roughness of the machined surface.Key Words: Chatter, Cutting Conditions, Stable Cutting, Surface Roughness.

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.

An Approach to Improve Cutting Performance in Micromilling of Titanium Alloy

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
Yunn-Shiuan Liao ◽  
Tsung-Hsien Li ◽  
Yi-Chen Liu
Keyword(s):  
Carbon Dioxide ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Liquid Carbon ◽  
Dry Cutting ◽  
Machined Surface ◽  
Liquid Carbon Dioxide

Abstract Application of liquid carbon dioxide to improve cutting performance in micro-end milling of Ti-6Al-4V titanium alloy was proposed in this study. It was found that the machined roughness decreased with the cutting speed as observed in the conventional cutting, when a 0.5 mm diameter end milling cutter was used in dry cutting. But, the tiny and shattered chips produced by the use of 0.3 mm diameter cutter could adhere on the machined surface and deteriorate surface finish, if the cutting speed was higher than 40 m/min. Cutting temperature was effectively decreased by applying liquid carbon dioxide during micromilling, which in turn reduced the amount of chips adhering on the machined surface and lowered flank wear. The surface roughness Ra at a cutting speed of 70 m/min was improved from 0.09 μm under dry cutting to 0.04 μm under the liquid carbon dioxide assisted cutting condition. And there were no flank wear and very few burrs left on the machined surface for the condition used in the experiment. The height of the burrs was only 25% of that under dry cutting. More, minimum quantity lubrication (MQL) was proposed to be applied together with the liquid carbon dioxide to enhance lubrication effect. It was noted that the machined surface roughness was further decreased by 15% as compared with that when the liquid carbon dioxide was applied alone. The height of burrs was reduced from 32 μm to 16 μm.

ANALYSIS OF THE CORRELATION BETWEEN FRACTAL STRUCTURE OF CUTTING FORCE SIGNAL AND SURFACE ROUGHNESS OF MACHINED WORKPIECE IN END MILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (02) ◽  
pp. 1950013 ◽  
Author(s):  
AHMAD THUFFAIL THASTHAKEER ◽  
ALI AKHAVAN FARID ◽  
CHANG TECK SENG ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Forces ◽  
End Milling ◽  
Complex Structure ◽  
Machined Surface ◽  
End Mills ◽  
Machining Operations

Analysis of the machined surface is one of the major issues in machining operations. On the other hand, investigating about the variations of cutting forces in machining operation has great importance. Since variations of cutting forces affect the surface quality of machined workpiece, therefore, analysis of the correlation between cutting forces and surface roughness of machined workpiece is very important. In this paper, we employ fractal analysis in order to investigate about the complex structure of cutting forces and relate them to the surface quality of machined workpiece. The experiments have been conducted in different conditions that were selected based on cutting depths, type of cutting tool (serrated versus. square end mills) and machining conditions (wet and dry machining). The result of analysis showed that among all comparisons, we could only see the correlation between complex structure of cutting force and the surface roughness of machined workpiece in case of using serrated end mill in wet machining condition. The employed methodology in this research can be widely applied to other types of machining operations to analyze the effect of variations of different parameters on variability of cutting forces and surface roughness of machined workpiece and then investigate about their correlation.

Experimental Study on Wear-Resistance of Machined Surface in High Speed Milling Aviation Aluminum Alloy

2012 ◽  
Vol 500 ◽  
pp. 117-122
Author(s):  
Xiu Li Fu ◽  
Xiao Qin Wang ◽  
Yong Zhi Pan ◽  
Yang Qiao
Keyword(s):  
Wear Resistance ◽  
Aluminum Alloy ◽  
Friction Coefficient ◽  
Surface Quality ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machined Surface ◽  
Resistance Performance

The wear-resistance performance of machined surface is an important factor in the evaluation of surface quality and precision in aerospace manufacturing industry. By using high-speed Ring-Block friction and wear machine (MRH-3), the influence of cutting parameters in milling aluminum alloy 7050-T7451 on wear-resistance of machined surface including friction coefficient and wear quantity are experimentally investigated. The wear-resistance is particularly sensitive to cutting speed and feed rate. The friction coefficient has marked drop trends as cutting speed increases. The influence of cutting speed on wear quantity is more complicated and the tendency of wear quantity was ascend in first and descend at last (v>900/min). The results show that the influence of cutting parameters on wear-resistance was also positively correlated with surface roughness and work-hardening of machined surface. The high work-hardening and surface quality had the promoting effecting on wear-resistance. The experiment and analysis results show that the machined surface by high speed cutting and lower feed rate has more superior in surface quality and wear-resistance performance comparing with conventional cutting speed.

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