scholarly journals Effect of the Relative Position of the Face Milling Tool towards the Workpiece on Machined Surface Roughness and Milling Dynamics

2019 ◽  
Vol 9 (5) ◽  
pp. 842 ◽  
Author(s):  
Danil Pimenov ◽  
Amauri Hassui ◽  
Szymon Wojciechowski ◽  
Mozammel Mia ◽  
Aristides Magri ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Relative Position ◽  
Cutting Forces ◽  
Face Milling ◽  
Machined Surface ◽  
Face Mill ◽  
The Face ◽  
Cutting Force Components ◽  
Force Components

In face milling one of the most important parameters of the process quality is the roughness of the machined surface. In many articles, the influence of cutting regimes on the roughness and cutting forces of face milling is considered. However, during flat face milling with the milling width B lower than the cutter’s diameter D, the influence of such an important parameter as the relative position of the face mill towards the workpiece and the milling kinematics (Up or Down milling) on the cutting force components and the roughness of the machined surface has not been sufficiently studied. At the same time, the values of the cutting force components can vary significantly depending on the relative position of the face mill towards the workpiece, and thus have a different effect on the power expended on the milling process. Having studied this influence, it is possible to formulate useful recommendations for a technologist who creates a technological process using face milling operations. It is possible to choose such a relative position of the face mill and workpiece that will provide the smallest value of the surface roughness obtained by face milling. This paper shows the influence of the relative position of the face mill towards the workpiece and milling kinematics on the components of the cutting forces, the acceleration of the machine spindle in the process of face milling (considering the rotation of the mill for a full revolution), and on the surface roughness obtained by face milling. Practical recommendations on the assignment of the relative position of the face mill towards the workpiece and the milling kinematics are given.

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

scholarly journals High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2196
Author(s):  
Marcin Płodzień ◽  
Łukasz Żyłka ◽  
Paweł Sułkowicz ◽  
Krzysztof Żak ◽  
Szymon Wojciechowski
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Vibration Amplitude ◽  
Experimental Tests ◽  
Face Milling ◽  
Machining Efficiency ◽  
High Feed ◽  
Cutting Force Components ◽  
42Crmo4 Steel ◽  
Force Components

High feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the high feed milling (HFM), experimental tests were conducted, preceded by an analysis of cutting zones when milling with an HF face cutter. The face milling tests of 42CrMo4 steel with the use of an HF cutter characterized by an entering angle, dependent on axial depth of cut ap and insert radius r values, as well as with a conventional face cutter with the entering angle of 45° were performed. The study focused on analyzing the vibration amplitude, cutting force components in the workpiece coordinate system, and surface roughness. The experimental tests proved, that when milling with constant cut layer thickness, the high feed cutter allowed to obtain twice the cutting volume in comparison with the conventional face cutter. However, higher machining efficiency resulted in an increase in cutting force components. Furthermore, the results indicate significantly higher surface roughness and higher vibration amplitudes when milling with the HF cutter.

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.

INFLUENCE ON THE FEED-RATE AND MQF IN THE SURFACE ROUGHNESS AND CUTTING FORCE COMPONENTS DURING THE AISI 420C TURNING WITH STANDARD AND WIPER TOOLS.

2015 ◽  
Author(s):  
André Faraon Rodrigues ◽  
Cássio Magalhães dos Reis ◽  
Matheus Nunes Duran ◽  
Guilherme Cortelini da Rosa ◽  
André João de Souza
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Force Components ◽  
Force Components

Modelling and Analysis of Relationship between Cutting Parameters Surface Roughness and Cutting Forces Using Response Surface Methodology when Hard Turning with Coated Ceramic Inserts

2016 ◽  
Vol 686 ◽  
pp. 19-26 ◽  
Author(s):  
Ildikó Maňková ◽  
Marek Vrabeľ ◽  
Jozef Beňo ◽  
Mária Franková
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Hard Turning ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Oxide Ceramic ◽  
Cutting Force Components ◽  
Force Components

Experimental research and modeling in the field of turning hardened bearing steel with hardness of 62 HRC using TiN coated mixed oxide ceramic inserts is presented. The main objective of the article is investigation the relationship between cutting parameters (cutting speed and feed rate) and output machining variables (surface roughness and cutting force components) through the response surface methodology (RSM). The mathematical model of the effect of process parameters on the cutting force components and surface roughness is presented. Moreover, the influence of TiN coating on above mentioned variables was monitored. The design of experiment according to Taguchi L9 orthogonal matrix (32) was applied for trials. Pearson´s correlation matrix was used to examine the dependence between the factors (f, vc) and the machining variables (surface roughness and cutting force components). The results show how much surface roughness and cutting force components is influenced by cutting speed and feed in hard turning with coated ceramics.

An Experimental Study on Cutting Forces in the Threading and the Side Cut Turning With Coated and Uncoated Grades

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
Firat Kafkas
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Three Dimensional ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Dynamic Force ◽  
Low Alloy Steels ◽  
Workpiece Material ◽  
Cutting Force Components ◽  
Force Components

The objective of this study is to obtain the cutting force components on the threading insert. The cutting force data used in the analysis are measured by a three-dimensional dynamic force dynamometer. The AISI 4140 and AISI 4340 low alloy steels are selected for the experiment on the threading and the side cut turning. The inserts used for testing is the TiAlN coated and uncoated grades. LT22NR35ISO type insert is used in the experiment. During the experiments, no cutting fluid and a constant spindle speed is used. The thread pitch and the depth of cut were kept fixed at 3.5 mm and 0.05 mm for the radial feed per pass, respectively. The study emphasizes on the effects on the workpiece material and the cutting tool grade of the cutting force components that occur during the threading. Also, these results are compared with the findings that are obtained during the side cut turning. It is determined that the measured primary cutting and radial forces during the threading are approximately three times bigger than those during the side cut turning, although feed forces during the threading are approximately 30 times lower compared with the side cut turning. The TiAlN coated WC/Co grade shows the best performance with respect to the cutting force components. The specific cutting forces are determined in order to understand the interference of chips that occur during the threading. With the increase in the cumulative radial feed, the corresponding specific cutting forces become higher. It is reasoned that the difference in the specific cutting forces results from the alteration of the interference of the flowing chips. The specific cutting forces decrease in the beginning of the threading and then increases with the cumulative radial feed. The results show that the interference of the chip flow influences the threading force components to a very large extent.

Effects of AlCl3 Additive on Cutting Forces and Diamond Wear Rate While Cutting Granite With a Single Diamond

1980 ◽  
Vol 102 (1) ◽  
pp. 12-17
Author(s):  
F. C. Appl ◽  
B. N. Rao ◽  
B. H. Walker
Keyword(s):  
Wear Rate ◽  
Cutting Force ◽  
Aluminum Chloride ◽  
Cutting Forces ◽  
Surfactant Solution ◽  
Cutting Fluid ◽  
Diamond Cutting ◽  
Cutting Force Components ◽  
Force Components ◽  
Diamond Cutting Tool

The effects of surfactant solution aluminum chloride on cutting granite rock with a diamond were investigated experimentally. Tests were conducted by cutting on the cylindrical surface of a granite cylinder in a lathe with a single spherically shaped diamond cutting tool. The cutting fluid consisted of various concentrations of aluminum chloride in deionized distilled water. The cutting force components were determined by means of a tool post dynamometer and were recorded continuously during the tests. Diamond wear was determined by periodically photographing the wear flat through an optical miscroscope. Results indicate that cutting forces and diamond wear rate are influenced by the additive. The normal cutting force is maximum at a concentration of 7 × 10−6 molar, and the tangential cutting force is maximum at 3 × 10−6 while the diamond wear rate is minimum at 3 × 10−6 molar. It is also found that there is an effect of concentration on relative tool life for constant depth cutting, but that maximum life occurs at higher levels of concentration.

scholarly journals Cutting Forces Prediction in the Dry Slotting of Aluminium Stacks

2014 ◽  
Vol 797 ◽  
pp. 47-52
Author(s):  
Jorge Salguero ◽  
Madalina Calamaz ◽  
Moisés Batista ◽  
Franck Girot ◽  
Mariano Marcos Bárcena
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Parametric Models ◽  
Cutting Process ◽  
Cutting Force Components ◽  
Force Components ◽  
Input Variables ◽  
The Individual

Cutting forces are one of the inherent phenomena and a very significant indicator of the metal cutting process. The work presented in this paper is an investigation of the prediction of these parameters in slotting processes of UNS A92024-T3 (Al-Cu) stacks. So, cutting speed (V) and feed per tooth (fz) based parametric models, for experimental components of cutting force, F(fz,V) have been proposed. These models have been developed from the individual models extracted from the marginal adjustment of the cutting force components to each one of the input variables: F(fz) and F(V).

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