scholarly journals The Comparative Study on Cutting Performance of Different-Structure Milling Cutters in Machining CFRP

2018 ◽  
Vol 8 (8) ◽  
pp. 1353
Author(s):  
Tao Chen ◽  
Fei Gao ◽  
Suyan Li ◽  
Xianli Liu
Keyword(s):  
Carbon Fiber ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Edge ◽  
Cutting Performance ◽  
Machining Process ◽  
Carbon Fiber Composites ◽  
Machined Surface ◽  
Milling Cutter ◽  
Machined Surface Quality

Carbon fiber reinforced plastic (CFRP) is typically hard to process, because it is easy for it to generate processing damage such as burrs, tears, delamination, and so on in the machining process. Consequently, this restricts its wide spread application. This paper conducted a comparative experiment on the cutting performance of the two different-structure milling cutters, with a helical staggered edge and a rhombic edge, in milling carbon fiber composites; analyzed the wear morphologies of the two cutting tools; and thus acquired the effect of the tool structure on the machined surface quality and cutting force. The results indicated that in the whole cutting, the rhombic milling cutter with a segmented cutting edge showed better wear resistance and a more stable machined surface quality. It was not until a large area of coating shedding occurred, along with chip clogging, that the surface quality decreased significantly. At the stage of coating wear, the helical staggered milling cutter with an alternately arranged continuous cutting edge showed better machined surface quality, but when the coating fell off, its machined surface quality began to reveal damage such as groove, tear, and fiber pullout. Meanwhile, burrs occurred at the edge and the cutting force obviously increased. By contrast, for the rhombic milling cutter, both the surface roughness and cutting force increased relatively slowly.

Study on the cutting performance in machining assembled hardened steel workpiece with torus cutter

2019 ◽  
Vol 234 (4) ◽  
pp. 701-709
Author(s):  
Tao Chen ◽  
Weijie Gao ◽  
Guangyue Wang ◽  
Xianli Liu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Surface Quality ◽  
Wear Mechanism ◽  
Hardened Steel ◽  
Cutting Performance ◽  
Machining Process ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Two Sides

Torus cutters are increasingly used in machining high-hardness materials because of high processing efficiency. However, due to the large hardness variation in assembled hardened steel workpiece, the tool wear occurs easily in machining process. This severely affects the machined surface quality. Here, we conduct a research on the tool wear and the machined surface quality in milling assembled hardened steel mold with a torus cutter. The experimental results show the abrasive wear mechanism dominates the initial tool wear stage of the torus cutter. As the tool wear intensifies, the adhesive wear gradually occurs due to the effect of alternating stress and impact load. Thus, the mixing effect of the abrasive and adhesive wears further accelerates tool wear, resulting in occurrence of obvious crater wear band on the rake face and coating tearing area on the flank face. Finally, the cutter is damaged by the fatigue wear mechanism, reducing seriously the cutting performance. With increase of flank wear, moreover, there are increasingly obvious differences in both the surface morphology and the cutting force at the two sides of the joint seam of the assembled hardened steel parts, including larger height difference at the two sides of the joint seam and sudden change of cutting force, as a result, leading to decreasing cutting stability and deteriorating seriously machined surface quality.

Optical Effects of Surface Finish by Ultraprecision Single Point Diamond Machining

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
Lei Li ◽  
Stuart A. Collins ◽  
Allen Y. Yi
Keyword(s):  
Surface Quality ◽  
Single Point ◽  
Diamond Turning ◽  
Optical Diffraction ◽  
Machining Process ◽  
Machined Surface ◽  
Tool Marks ◽  
Tool Mark ◽  
Machined Surface Quality ◽  
Machined Surfaces

The single point diamond turning process has been used extensively for direct optical surface fabrication. However, the diamond machined surfaces have characteristic periodic tool marks, which contribute to reduced optical performance such as scattering and distortion. In this paper, studies of the characteristics of diamond machined surface and scattering from the diamond machined surfaces are presented. Four different parameters, the first order optical diffraction, the zero order reflection, the surface roughness, and the residual tool mark depth, are used as indicators for the machined surface quality. Four sets of tests are presented showing the relationship between machined surface quality and machining conditions such as spindle speed, feedrate, and machining process. Finally, an empirical model is given based on the measurements.

scholarly journals Surface Roughness Analysis of H13 Steel during Electrical Discharge Machining Process Using Cu–TiC Sintered Electrode

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 5943
Author(s):  
Arminder Singh Walia ◽  
Vineet Srivastava ◽  
Mayank Garg ◽  
Nalin Somani ◽  
Nitin Kumar Gupta ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Electrical Discharge ◽  
Pulse Current ◽  
Electrical Discharge Machining ◽  
Machining Process ◽  
H13 Steel ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Semi Empirical

In electrical discharge machining (EDM), the machined surface quality can be affected by the excessive temperature generation during the machining process. To achieve a longer life of the finished part, the machined surface quality plays a key role in maintaining its overall integrity. Surface roughness is an important quality evaluation of a material’s surface that has considerable influence on mechanical performance of the material. Herein, a sintered cermet tooltip with 75% copper and 25% titanium carbide was used as tool electrode for processing H13 steel. The experiments have been performed to investigate the effects of EDM parameters on the machined surface roughness. The findings show that, as the pulse current, pulse length, and pulse interval are increased, the surface roughness tends to rise. The most significant determinant for surface roughness was found to be pulse current. A semi-empirical surface roughness model was created using the characteristics of the EDM technique. Buckingham’s theorem was used to develop a semi-empirical surface roughness prediction model. The semi-empirical model’s predictions were in good agreement with the experimental studies, and the built empirical model based on physical features of the cermet tooltip was tested using dimensional analysis.

scholarly journals Pulsed Magnetic Field Treatment of TiAlSiN Coated Milling Tools For Improved Cutting Performances

2021 ◽  
Author(s):  
Hao Qu ◽  
Lin Zhang ◽  
Zhe Chen ◽  
Lei Zhang ◽  
Kyle Jiang ◽  
...  
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Cutting Force ◽  
Processing Parameters ◽  
Cutting Performance ◽  
Machining Process ◽  
Pulsed Magnetic Field ◽  
Machined Surface ◽  
Wear Area ◽  
Cutting Vibration

Abstract In this study a pulsed magnetic treatment was attempted to improve the cutting performance of the TiAlSiN coated WC-12wt%Co cemented carbide end mills and the effects of the strength of the pulsed magnetic field on the cutting forces, the cutting vibrations, the tool wear, the machined surface roughness and mechanical properties were investigated. It is found that the cutting performances of the coated tools are successfully improved with a relatively lower cutting force and less wear area. The average resultant cutting force Fxyave decrease by 14.53% in the last machining process when the optimum processing parameters of 0.5T magnetic field is used, accompanying a maximum decrease of 46.8% in the cutting vibration. The maximum reductions of 57.65% and 25.4% in the flank wear and the average surface roughness of the workpiece are obtained respectively after the treatment. Both the hardness and toughness of the cemented carbides are slightly improved with the imposition of the field. The improvements in the cutting performance of the tool are attributed to the enhanced adhesion strength between the coating and matrix, which is caused by the increased compressive residual stress induced by the PMT.

Development of SiO2 Nanolubrication System for Better Surface Quality, more Power Savings and Less Oil Consumption in Hard Turning of Hardened Steel AISI4140

2013 ◽  
Vol 748 ◽  
pp. 56-60 ◽  
Author(s):  
M. Sayuti ◽  
Ahmed A.D. Sarhan ◽  
S. Salem
Keyword(s):  
Power Consumption ◽  
Surface Quality ◽  
Hard Turning ◽  
Cnc Machining ◽  
Machining Process ◽  
Lubrication System ◽  
Turning Process ◽  
Oil Consumption ◽  
Machined Surface ◽  
Machined Surface Quality

In recent years, the energy efficiency improvement has become significant due to rapid consumption of world's energy resources. Particularly in manufacturing industry, hard turning process is one of the most fundamental metal removal processes that require huge power consumption and it could be improved in term of energy usage by many alternatives. At the same time, the improvement in term of machined surface quality is become a need since it would reflect appearance, performance and reliability of the products. As for example in the CNC machining field, one of the solution for this issue is by increasing the effectiveness of the existing lubrication systems as it could improve the machined surface quality, reduce the power required to overcome the friction component in batch production of machining process and reduce the oil consumption. The effectiveness of the lubrication system could be improved by introducing the nanobase lubrication system for much less power consumption as the rolling action of billions units of nanoparticle in the tool chip interface could reduce the cutting forces significantly. In this research work, the possibility of using SiO2 nanobase lubrication system is investigated to reduce the machining power consumption as well as improving surface quality in hard turning process of AISI4140.

Study of High Efficiency in Green Cutting Nickel-Based Superalloy GH4169

2010 ◽  
Vol 33 ◽  
pp. 555-559
Author(s):  
Rong Di Han ◽  
Hui Wang ◽  
Y. Zhang ◽  
Q.W. Yao
Keyword(s):  
Water Vapor ◽  
Tool Wear ◽  
Cutting Force ◽  
Surface Quality ◽  
Tool Life ◽  
Cutting Temperature ◽  
Dry Cutting ◽  
Machined Surface ◽  
Nickel Based Superalloy ◽  
Machined Surface Quality

The machinability of nickel-based superalloy GH4169 is very poor, the traditional machining of GH4169 using the cutting fluids with the active additives causes environmental and health problems, which is out of the request of the sustainable development strategy. In this paper a new green cutting technology with overheated water vapor as coolants and lubricants was proposed to achieve the aim of green cutting and high productivity. Cutting experiments and tool wear tests using carbide tool YG6 under dry cutting, emulsion and water vapor were performed. The cutting force, cutting temperature, machined surface quality and tool life were investigated; the curve of flank tool wear and relation between tool life and cutting velocity was carried out. The results of experiments indicated that during water vapor condition, the cutting force and cutting temperature was reduced, the machined surface roughness was improved, and the tool life was longed, respectively, and the higher velocity was taken during the some tool wear condition compared to dry cutting. The research results show that green cutting was achieved associated with overheated water vapor cooling and lubricating, at he same time the machined surface quality and production efficiency was increased.

Research on Machined Surface Quality of High Speed Hard Machining for Harden Steel

2012 ◽  
Vol 500 ◽  
pp. 82-88 ◽  
Author(s):  
Cai Xu Yue ◽  
Xian Li Liu ◽  
Da Wei Sun ◽  
Ming Yang Wu
Keyword(s):  
Surface Quality ◽  
High Speed ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Machining Process ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Machined Surface Quality ◽  
Side Flow

For its good processing flexible, economic and environmental protection performance, hardened steel GCr15 is used widely in car and energy industry. Although surface quality in machining process is not controlled well, that restricts application of hardened steel GCr15 extensive to a certain degree. Therefore, this study revealed the effect of cutting parameters on surface roughness. Also influence of cutting conditions on surface morphology and organization generation mechanism of subsurface were stuied for high-speed cutting hardened steel GCr15. Appear reasons of plastic side flow on surface was researched. Also, effect of tool wear on surface quality was studied as well. The research results provided theoretical basis for rational choice for high speed hardened steel cutting process.

scholarly journals Influence of Lubricant Environment on Machined Surface Quality in Single-Point Diamond Turning of Ferrous Metal

Micromachines ◽  
2021 ◽  
Vol 12 (9) ◽  
pp. 1110
Author(s):  
Menghua Zhou ◽  
Jianpeng Wang ◽  
Guoqing Zhang
Keyword(s):  
Surface Morphology ◽  
Cutting Force ◽  
Surface Quality ◽  
Single Point ◽  
Ferrous Metal ◽  
Minimum Quantity Lubrication ◽  
Diamond Turning ◽  
Machined Surface ◽  
Hard Particles ◽  
Machined Surface Quality

In the field of single-point diamond turning (SPDT), machining ferrous metal is an important research topic with promising application. For SPDT of ferrous metal, the influence of lubricant on the workpiece surface morphology remains to be studied. In this study, three lubricant machining environments were selected to carry out specific control experiments. The machined surface morphology and cutting force in different lubricant machining environments were analyzed. The experiment results showed that the lubricant environment will have significant impacts on the quality of the machined surface morphology of ferrous metal. In the environment of minimum quantity lubrication machining (MQLM-oil), better machined surface quality can be obtained than that in ordinary dry machining (ODM) and high-pressure gas machining (HGM). Furthermore, the cutting force captured in the ODM and HGM environment increased with the increase of the cutting depth, while the cutting force in the MQLM-oil environment remained almost unchanged. That indicates MQLM-oil can suppress the formation of hard particles to improve the machining quality.

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