scholarly journals Optimization of Cutting Data and Tool Inclination Angles During Hard Milling with CBN Tools, Based on Force Predictions and Surface Roughness Measurements

Materials ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1109 ◽  
Author(s):  
Andrzej Matras ◽  
Wojciech Zębala
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Machining Process ◽  
Free Form ◽  
Inclination Angles ◽  
Cutting Force Components ◽  
Force Components ◽  
Feed Rate Optimization ◽  
Roughness Measurements

This work deals with technological considerations required to optimize the cutting data and tool path pattern for finishing the milling of free-form surfaces made of steel in a hardened state. In terms of technological considerations, factors such as feed rate, workpiece geometry, tool inclination angles (lead and tilt angles) and surface roughness are taken into account. The proposed method is based on calculations of the cutting force components and surface roughness measurements. A case study presented in the paper is based on the AISI H13 steel, with hardness 50 HRC and milling with a cubic boron nitride (CBN) tool. The results of the research showed that by modifications of the feed value based on the currently machined cross-sectional area, it is possible to control the cutting force components and surface roughness. During the process optimization, the 9% and 15% increase in the machining process efficiency and the required surface roughness were obtained according to the tool inclination angle and feed rate optimization procedure, respectively.

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.

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

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.

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.

Empirical study on ultrasonic assisted turn-milling

2021 ◽  
pp. 095440892110087
Author(s):  
Saeid Amini ◽  
Mohammad Baraheni ◽  
Mohammad Khaki
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Feed Rate ◽  
Rotational Speed ◽  
Milling Process ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Turn Milling

Turn-milling process has been paid attention in order to be used in multi-task machining processes. Moreover, looking for new machining techniques aimed at reducing cutting force is of important. Reducing cutting force in machining processes has the benefits of extending tool life and improving surface quality. One of the new concepts for reducing the cutting force is applying ultrasonic vibration. In this paper, effects of ultrasonic vibration under different machining parameters in turn-milling process of Al-7075 alloy will be investigated. In this order, a special mechanism was designed to apply ultrasonic vibration during machining process. Ultrasonic vibration exertion on the tool reduced cutting force and surface roughness up to 75% and 35%, respectively. Also tool rotational speed increment induced cutting force and surface roughness increment. In addition, tool feed rate and workpiece rotational speed increment caused cutting force and surface roughness increment. Although, feed rate was more influential.

Force Modeling and Control of SiC Monocrystal Wafer Processing

2015 ◽  
Vol 137 (6) ◽  
Author(s):  
Shujuan Li ◽  
Siming Du ◽  
Aofei Tang ◽  
Robert G. Landers ◽  
Yang Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Normal Force ◽  
Control Variable ◽  
Contact Length ◽  
Machining Process ◽  
Model Parameters ◽  
Wire Saw ◽  
The Wire

Wire saws with fixed diamond abrasive are often used to cut hard and brittle materials owning to the wire saw's narrow kerf, low cutting force, and minimal material waste. Typically, the cutting force changes during the operation since the part diameter and the contact length between the wire saw and part (i.e., contact length) continuously change, even if the process parameters (i.e., wire saw velocity, part feed rate, part rotation speed, and wire saw tension) are fixed, leading to wire saw breakage, wafer collapse, and inferior surface roughness. This study addresses this issue by regulating the force via feedback control. The most significant process parameter affecting the normal force, namely, part feed rate, is taken as the control variable. A system identification routine is used to obtain the transfer function relating the normal force and commanded part feed rate and the model parameters are identified online. An adaptive force controller is designed, and simulation and experimental studies for SiC monocrystal wafer wire saw machining are conducted. The results show the dynamic model well characterizes the normal force generated when wire saw machining SiC monocrystal, and the adaptive controller can effectively track various normal reference force trajectories (i.e., constants, ramps, and sine waves). The experimental results demonstrate that the wire saw machining process with adaptive force control can improve the cutting productivity and significantly decrease wafer surface roughness as compared to the cutting process with a constant part feed rate.

Cutting Performance and Predictive Models for End Milling Aluminum Alloy

2009 ◽  
Vol 83-86 ◽  
pp. 646-653
Author(s):  
Chung Chen Tsao
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
Predictive Models ◽  
Feed Rate ◽  
Flank Wear ◽  
End Milling ◽  
Correlation Coefficients ◽  
Helix Angle ◽  
Machining Process

End milling is considered to be one of the most commonly applied for both roughing and finishing operations to make flat surfaces, slots and pockets in precision molds and dies. Predictive models were developed for cutting force, flank wear and surface roughness in end milling aluminum alloy by regression analysis. The correlation coefficients for cutting force, flank wear and surface roughness equations were 91.6 %, 89.8 % and 79.6 %, respectively. The goal of these predictive equations is to become a good assistant to the researcher in understanding the machining process. Through the analysis of variance (ANOVA), however, it can be found that the cutter diameter, the helix angle and the feed rate are the important milling process parameters to obtain the machined quality on cutting force, flank wear and surface roughness. The investigations show that cutting force, flank wear and surface roughness can be improved in end milling aluminum alloy by using the lower cutter diameter, medium helix angle and lower feed rate.

Analysis of surface roughness and cutting force components in hard turning with CBN tool: Prediction model and cutting conditions optimization

Measurement ◽  
2012 ◽  
Vol 45 (3) ◽  
pp. 344-353 ◽  
Author(s):  
Hamdi Aouici ◽  
Mohamed Athmane Yallese ◽  
Kamel Chaoui ◽  
Tarek Mabrouki ◽  
Jean-François Rigal
Keyword(s):  
Surface Roughness ◽  
Prediction Model ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Conditions ◽  
Cbn Tool ◽  
Cutting Force Components ◽  
Force Components

Prediction of cutting force in micro-end-milling by a combination of analytical and FEM method

2020 ◽  
Vol 3 (1) ◽  
pp. 28-38
Author(s):  
Ashutosh Roushan ◽  
U. S. Rao ◽  
L. Vijayaraghavan
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Feed Force ◽  
Micro End Milling ◽  
Cutting Force Components ◽  
Micro Features ◽  
Force Components ◽  
Aisi 4340

Mechanical micro-machining, in general, and micro-end-milling, in particular, has become a very good technique for fabricating 3D micro-features in a variety of materials. To optimize and control the process, prediction of the cutting force accurately is very important. In this work, a force prediction model is developed by a combination of analytical method and finite element (FE) simulations. The model predicts the cutting force components for micro-end-milling process successfully which is compared with experimental force signal obtained by using Al2024-T3 and AISI 4340 as workpiece materials. The predicted and experimental cutting forces are in very good agreement for both the amplitude and trend of the cutting force. The percentage deviation of the predicted force from the experimental force values for both feed force ( Fx) and transverse force ( Fy) is around 15% (except one case) for Al2024-T3. For the AISI 4340 material, the percentage deviation for Fx is around 25% and for Fy is approximately 10%. The methodology followed here is general in nature and it can be applied to any other machining process as well.

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