scholarly journals Experimental Investigation on the Effect of Different Micro-Geometries on Cutting Edge and Wiper Edge on Surface Roughness and Forces in Face Milling

Lubricants ◽  
2021 ◽  
Vol 9 (10) ◽  
pp. 102
Author(s):  
Padmakumar Muthuswamy ◽  
Sathish Kumar Nagarajan
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Metal Cutting ◽  
High Carbon Steel ◽  
High Stress ◽  
Radial Force ◽  
Face Milling ◽  
Cutting Edge ◽  
Critical Surface ◽  
Element Analysis

The significance of the micro-geometries on the cutting edge is known from numerous studies conducted in the past. However, the effect of micro-geometry on the wiper facet (also called the wiper edge) is not known. Hence, this paper investigates the effect of different micro-geometries with a focus on geometry variation on the wiper edge of a milling insert on surface roughness and forces in face milling of SAE1070 high-carbon steel. Milling inserts with sharp, rounded, chamfered edges and their combinations were manufactured on the cutting edge and wiper edge for the study. Critical surface quality parameters such as the average surface roughness (Ra), mean depth of surface roughness (Rz), and force components such as radial force (Fx), cutting force (Fy), and axial force (Fz) were evaluated. Metal cutting tests were performed at three different cutting speeds and three different feed rates to study the influence of cutting parameters and the effect of edge geometries on surface roughness. The results were correlated with the force values to understand the machining dynamics. Finite element analysis was performed to evaluate the high and low-stress zones on the insert, workpiece, and chip to understand the metal cutting mechanism of different micro-geometries. The novel finding from the study is that having identical micro-geometries on the cutting and wiper edge is the preferred combination, whereas dissimilar micro-geometries result in reduced surface quality, increased forces, and high stress on the workpiece and chip.

Statistical Research on the Effects of Cutting Edge Preparation on Face Milling of Austenitic Stainless Steel Using FEM

2009 ◽  
Vol 407-408 ◽  
pp. 516-520
Author(s):  
Wei Wei Ming ◽  
Ming Chen
Keyword(s):  
Cutting Force ◽  
Stainless Steels ◽  
Austenitic Stainless Steels ◽  
Face Milling ◽  
Cutting Edge ◽  
Statistical Research ◽  
Element Analysis ◽  
Tool Edge ◽  
Cutting Edge Preparation ◽  
Edge Preparation

Austenitic stainless steels are extensively used in the areas with high corrosion. The high heat resistance and strength make them difficult-to-cut materials. The tool life in machining austenitic stainless steels is restricted by the high cutting force and temperature which induce the tool wear and edge chipped. To achieve tool edge strength and reduce the edge-related problems, tool edge preparation is applied by introducing the chamfered and honed edges. In the current paper, the effects of the cutting edge preparation in face milling of austenitic stainless steels were studied using statistical method. The output cutting parameters as cutting force, temperature were obtained by finite element analysis. The purpose for this research is to give guidance to the tool edge preparation for machining stainless steels.

The Surface Quality Detection and Electrical Discharge Mirror Machining with Non-Mixed-Powder

2015 ◽  
Vol 775 ◽  
pp. 214-218
Author(s):  
Yuan Lin ◽  
Hao Jiang ◽  
Huan Ran Lv ◽  
Xiu Wu Sui
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Electrical Discharge ◽  
Measuring Method ◽  
Work Piece ◽  
Analysis Method ◽  
Element Analysis ◽  
Mixed Powder ◽  
Quality Detection ◽  
The Impact

By using analytical and finite element analysis method, this paper analyzes the various factors on the impact of EDM surface roughness, puts forward a new mirror machining method of changing the order of the processing conditions and increasing the momentum of the swinging electrode in the process of EDM. Puts a measuring method for the surface quality with white light interferometer characterized by non-contact, high precision and vertical resolution in nanometer. Experiments show that in the non-mixed powder fluid, without replacing the electrodes and the processed work-piece is 45 # steel, the surface roughness of work-piece is 0.02 micro-meter, which meets the requirements for precision of the electrical discharge mirror machining.

Research on Cutting Force and Surface Roughness in Face Milling Ni-Based Superalloy

2012 ◽  
Vol 588-589 ◽  
pp. 1698-1701
Author(s):  
Hui Wang ◽  
Feng Zhou ◽  
Rong Di Han
Keyword(s):  
Surface Roughness ◽  
Water Vapor ◽  
Environmental Pollution ◽  
Metal Cutting ◽  
Face Milling ◽  
Cutting Fluids ◽  
Dry Cutting ◽  
Milling Force ◽  
Oil Emulsion ◽  
Nickel Based Superalloy

The machinability of Nickel-based superalloy GH4169 is poor, the traditional methods to machining is application of cutting fluids with the active additives which cause environmental pollution and health problems. In this paper, the water vapor was applied on milling instead of cutting fluids for the aim of green milling GH4169. The effects of water vapor, oil emulsion and dry cutting on milling force and the surface roughness have been examined with carbide tools YG6A. The results of experiments indicated that application of water vapor produced lower milling force, the values were reduced about 7 percent compared to dry cutting, and it is advantage in surface roughness. The research results show that clean production was achieved in metal cutting associated with water vapor cooling and lubricating.

Determination of Constitutive Equation Parameters for Face Milling 3-D Simulation via Pressure Bar and Orthogonal Cutting Tests

2012 ◽  
Vol 723 ◽  
pp. 136-142 ◽  
Author(s):  
Sha Liu ◽  
Jian Fu Zhang ◽  
Ping Fa Feng ◽  
Ding Wen Yu ◽  
Zhi Jun Wu
Keyword(s):  
Constitutive Equation ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Material Model ◽  
Milling Process ◽  
Face Milling ◽  
Cutting Process ◽  
Element Analysis ◽  
The Face ◽  
Pressure Bar

Material constitutive equation plays an important role in Finite Element Analysis (FEA) of metal cutting process. This paper proposes a method to obtain parameters for Power Law model of a Japanese type of alloy steel (SCM440H) for 3-D FEA of face milling process, involving pressure bar experiments and orthogonal metal cutting experiments. Since pressure bar test cannot reach the high strain rate occurred in cutting process, orthogonal cutting experiment was combined to obtain parameters for material model. By this method, the ideal parameters for FEA of the face milling process were finally determined. Face milling experiments were performed to verify the accuracy of the model built.

scholarly journals PENENTUAN KECEPATAN PEMOTONGAN EFEKTIF BERDASARKAN NILAI KEKASARAN PERMUKAAN MATERIAL AA-7075 PADA PROSES FACE MILLING

POROS ◽  
2021 ◽  
Vol 17 (1) ◽  
pp. 51
Author(s):  
Sobron Y. Lubis ◽  
Rosehan Rosehan ◽  
Musa Law
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Feed Rate ◽  
Tooth Development ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Machining Parameters ◽  
Aa 7075 ◽  
Aluminum Alloy 7075

During face milling machining, several machining parameters such as feed rate and cuttingspeed determine the surface quality of the workpiece produced by the process. The selection of the rightparameters will lead to the surface quality as planned. Therefore, to improve machining effectiveness, amethod is needed to determine the appropriate machining parameters to produce the desired surfacequality. This research was conducted using a milling machine, five variations of cutting speed and fivevariations of feed rate were used to cut the workpiece aluminum alloy 7075. After machining, the surfaceroughness was measured using a surface test. The surface roughness value is then substituted into thefeed rate equation and effective cutting speed. By finding effective cutting parameters, the machiningprocess will be more efficient and effective without using unnecessary resources. From the results of thestudy note that the development equation to determine the feed rate based on the value of surfaceroughness is ???? = 0,6????√???? ????????0.443mm/tooth. Development equation to determine the effective cutting speedbased on Surface roughness value is ???????? = 3.0686????????0.124 mm/min

Analysis of the Behaviour Effect of Face Cutting Edge Inserts on Surface Roughness when Milling Steels with MQL Lubrication

2006 ◽  
Vol 526 ◽  
pp. 25-30
Author(s):  
Xavier Salueña Berna ◽  
Jose Antonio Ortiz Marzo ◽  
Jasmina Casals Terré
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Face Milling ◽  
Cutting Edge ◽  
Cutting Conditions ◽  
Surface Appearance ◽  
Milling Operations ◽  
Comparison Of The Results ◽  
Milling Tools

The main objectives of this work are the study of the obtained surface roughness on steels, using face cutting edge inserts milling tools in finishing face milling operations with microlubrication (MQL), and comparison of the results obtained with the widely-used radius inserts. This experimental study analyzes the roughness and surface appearance obtained with both sort of inserts. The interest about this study is to determine the steel types and the optimal cutting conditions for milling with this face cutting edge inserts. Another result analysed is the utility of the MQL implementation compared to the dry system.

scholarly journals Effect of the Side Cutting–Edge Angle on the Surface Roughness for Aluminum 1350 in the Turning Operation by Taguchi Method

2010 ◽  
Vol 8 (03) ◽  
Author(s):  
L. Rico ◽  
S. Noriega ◽  
J.L. García ◽  
E.A. Martínez ◽  
R. Ñeco ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Statistical Tests ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Research Directions ◽  
Turning Operation ◽  
Edge Angle ◽  
Major Variation ◽  
High Level

The purpose of this work was to analyze the effect of the side cutting-edge angle on the surface roughness of aluminum 1350 in a turning operation. A Taguchi design L32 was used in this work; the control variables were spindlespeed, feed rate, depth of cutting and the side cutting-edge angle. Several metal cutting experiments and statistical tests provide evidence that the side cutting-edge angle significantly affects the surface roughness with a Statistical F equal to 24.96, mainly, when the side cutting-edge angle is maintained at high level; in this study, the high level was kept to 5.0 degrees. Also, when the high level condition is kept, it causes a major variation of the residual values; consequently, the surface roughness of the workpiece falls out of the specifications demanded by customers.Moreover, the best combination of the cutting parameters for a minimum surface roughness equal to 23.5 μin wasobtained. Finally, further research directions are presented.

Comparison of Theoretical and Real Surface Roughness in Face Milling with Octagonal and Circular Inserts

2013 ◽  
Vol 581 ◽  
pp. 360-365 ◽  
Author(s):  
Csaba Felhő ◽  
János Kundrák
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Theoretical Data ◽  
Face Milling ◽  
Experimental Investigations ◽  
Real Surface ◽  
Roughness Parameters ◽  
Surface Roughness Parameters ◽  
Cutting Processes ◽  
Cutting Experiments

Various modeling techniques have applied by researchers to predict values of surface roughness parameters in different metal cutting processes. Some examples of these methods are briefly introduced. After this an analytical model and investigation method are presented which were used to make predictions of the expected values of surface roughness parameters. Cutting experiments were performed to obtain real roughness data and to validate the proposed and realised model by face milling of 42CrMo4 specimens with two different insert shapes. Conditions and results of these experimental investigations are presented in the subsequent part of the paper, and finally the determined approximation relations are introduced that can be used to calculate the expected roughness values from theoretical data.

Experiment and Finite Element Analysis Research on Surface Roughness in Micro-Grinding H62

2016 ◽  
Vol 1136 ◽  
pp. 21-29
Author(s):  
Xue Long Wen ◽  
Ya Dong Gong ◽  
Yao Sun ◽  
Jun Cheng ◽  
De Chun Ba
Keyword(s):  
Finite Element Analysis ◽  
Surface Roughness ◽  
Finite Element ◽  
Surface Quality ◽  
Influence Factors ◽  
Work Piece ◽  
Feed Speed ◽  
Element Analysis ◽  
Important Processing ◽  
Grinding Tool

Micro-grinding is an important processing method in micro-manufacturing field. The influence factors of surface quality in micro-grinding are discussed in the article. The models of finite element analysis (FEA) in micro-grinding H62 with electroplated CBN micro-grinding tool were established. The influence of different grinding factors on the surface quality of the work-piece was discussed by FEA. Different grains sizes were considered to reveal the influence rules on surface roughness in grinding experiments. The results show that the surface roughness decreases with the decreasing of the feed speed and the increasing of the grinding speed. A better surface quality can be achieved with smaller grains sizes. The minimum surface roughness can reach 481nm in side grinding H62.

Possible examinations of stone machining focused on the relationship between technological parameters and surface quality

2013 ◽  
Vol 4 (1) ◽  
pp. 63-68 ◽  
Author(s):  
Zs. Kun ◽  
I. G. Gyurika
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Theoretical Background ◽  
Motion Path ◽  
Depth Of Cut ◽  
Manufacturing Cost ◽  
Technological Parameters ◽  
The Relationship ◽  
Manufacturing Time

Abstract The stone products with different sizes, geometries and materials — like machine tool's bench, measuring machine's board or sculptures, floor tiles — can be produced automatically while the manufacturing engineer uses objective function similar to metal cutting. This function can minimise the manufacturing time or the manufacturing cost, in other cases it can maximise of the tool's life. To use several functions, manufacturing engineers need an overall theoretical background knowledge, which can give useful information about the choosing of technological parameters (e.g. feed rate, depth of cut, or cutting speed), the choosing of applicable tools or especially the choosing of the optimum motion path. A similarly important customer's requirement is the appropriate surface roughness of the machined (cut, sawn or milled) stone product. This paper's first part is about a five-month-long literature review, which summarizes in short the studies (researches and results) considered the most important by the authors. These works are about the investigation of the surface roughness of stone products in stone machining. In the second part of this paper the authors try to determine research possibilities and trends, which can help to specify the relation between the surface roughness and technological parameters. Most of the suggestions of this paper are about stone milling, which is the least investigated machining method in the world.

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