scholarly journals Influence of the Cutting Strategy on the Temperature and Surface Flatness of the Workpiece in Face Milling

Materials ◽  
2020 ◽  
Vol 13 (20) ◽  
pp. 4542
Author(s):  
Lukasz Nowakowski ◽  
Michal Skrzyniarz ◽  
Slawomir Blasiak ◽  
Marian Bartoszuk
Keyword(s):  
Aluminum Alloy ◽  
Face Milling ◽  
Depth Of Cut ◽  
Workpiece Material ◽  
Workpiece Surface ◽  
Workpiece Temperature ◽  
Surface Flatness ◽  
Calculation Results ◽  
Cutting Zone ◽  
Cutting Strategy

This article analyzes the temperature data obtained for an aluminum alloy face milled using four different cutting strategies. The workpiece temperature was measured at six points with K-type thermocouples. The heat transfer taking place in the cutting zone was also simulated numerically using the finite element method (FEM) and the finite difference method (FDM). The calculation results concerning the distribution of temperature on the workpiece surface were compared with the experimental data. The numerically simulated distribution of temperature on the workpiece surface after face milling was considered in relation to the surface flatness. The findings suggest that the flatness deviations at the workpiece ends were dependent on the depth of cut. Another reason was the cutting strategy selected for the specific thermophysical properties of the workpiece material. Measurement of the workpiece temperature is extremely important because of the thermoelastic behavior and thermal expansion of the material. The isotropic properties of the aluminum alloy make it expand in all directions during milling.

scholarly journals Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

2021 ◽  
pp. 71-84
Author(s):  
Nhu-Tung Nguyen ◽  
Dung Hoang Tien ◽  
Nguyen Tien Tung ◽  
Nguyen Duc Luan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
High Speed Milling

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

Machining Parameters Mapping’s of Inconel 718 and Aluminum Alloy 1100 in Micro-Milling Process

2020 ◽  
Vol 846 ◽  
pp. 99-104
Author(s):  
Gandjar Kiswanto ◽  
Maulana Azmi ◽  
Adrian Mandala ◽  
Dede Lia Zariatin ◽  
Tae Jo Ko
Keyword(s):  
Aluminum Alloy ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Manufacturing Cost ◽  
Machining Parameters ◽  
Workpiece Material

The development of micro-products in industry, like aviation, medical equipment, electronics, etc, has been increasing lately. The need for scaling down of product has been increasing to make the product simpler and complex. Micro-milling has capabilities in producing complex parts. In this study, mapping and comparing the result of the machining process of Inconel 718 and Aluminum Alloy 1100 was employed. In this experiment, Inconel 718 was used as workpiece material and the result of Aluminum Alloy taken from recent studies. Then, A cutting tool with a diameter 1 mm carbide coating TiAlN was used in this experiment. The machining process was performed with three varieties of spindle speed and feed rate with a constant depth of cut. After the machining is done, the mapping of the result surface roughness of Inconel 718 and AA1100 performed. It was found that Inconel 718 has poor machinability compared with AA 1100. Inconel 718 also has a high manufacturing cost compared to AA 1100 because the cutting tool was easy to wear.

An Investigation of Stability Analysis of Face Milling of Cantilever Plates at Low Cutting Speeds

2018 ◽  
Vol 17 (02) ◽  
pp. 213-229 ◽  
Author(s):  
Joel Martins Crichigno Filho ◽  
João Fabio Bortolanza
Keyword(s):  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Stable Region ◽  
Depth Of Cut ◽  
Workpiece Surface ◽  
Process Damping ◽  
Stability Lobes ◽  
The Stability ◽  
Cutting Speeds

Considering the production requirement of workpiece optimization in order to reduce mass, the dynamic behavior of a workpiece can be affected. This factor can influence the performance of the milling process due to the occurrence of chatter vibrations. On the other hand, when the recommended cutting speed is relatively low, the tool rubs against the workpiece surface causing process damping. Consequently, the process becomes more stable and hence the depth of cut can be increased. In this paper, the stability of face milling of a cantilever plate at low cutting speed is investigated. The stability lobes diagram is determined numerically considering process damping. Cutting tests are conducted in order to verify the simulated results. An accelerometer is attached to the workpiece and its signal is measured and analyzed. Both workpiece surface and roughness are also investigated. The experimental results show a good agreement with the stability lobes diagram to predict the stable region under process damping. Hence, the depth of cut can be considerably increased, keeping the process stable at low cutting speeds.

The Influence of Stretched Fixation on Face Milling-Machined 6061T6 Aluminum Alloy

2013 ◽  
Vol 589-590 ◽  
pp. 264-268 ◽  
Author(s):  
Wei Yi ◽  
Zhao Liang Jiang ◽  
Zhi Li ◽  
Bin Li ◽  
Wen Ping Liu
Keyword(s):  
Residual Stress ◽  
Aluminum Alloy ◽  
Surface Topography ◽  
Face Milling ◽  
Work Piece ◽  
Machining Parameters ◽  
Surface Residual Stress ◽  
Machined Surface ◽  
Surface Flatness ◽  
The Face

The influence of stretched fixation on face milling-machined 6061T6 aluminum alloy, a widely used material in industry, was investigated in the paper. A unidirectional stretched fixture was designed and used in the face milling experiments. During the experiments, the pre-stress exerted on the work-piece increased from 0 to 220MPa with other machining parameters being constant. Surface topography, surface residual stress and flatness were measured. The results reveal that stretched fixation has significantly effect on residual stress, machined surface flatness, and roughness.

scholarly journals An Investigation of the Cutting Strategy for the Machining of Polar Microstructures Used in Ultra-Precision Machining Optical Precision Measurement

Micromachines ◽  
2021 ◽  
Vol 12 (7) ◽  
pp. 755
Author(s):  
Chen-Yang Zhao ◽  
Chi-Fai Cheung ◽  
Wen-Peng Fu
Keyword(s):  
Precision Measurement ◽  
Detection Algorithm ◽  
Surface Generation ◽  
Precision Machining ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ultra Precision ◽  
Transition Points ◽  
Cutting Strategy

In this paper, an investigation of cutting strategy is presented for the optimization of machining parameters in the ultra-precision machining of polar microstructures, which are used for optical precision measurement. The critical machining parameters affecting the surface generation and surface quality in the machining of polar microstructures are studied. Hence, the critical ranges of machining parameters have been determined through a series of cutting simulations, as well as cutting experiments. First of all, the influence of field of view (FOV) is investigated. After that, theoretical modeling of polar microstructures is built to generate the simulated surface topography of polar microstructures. A feature point detection algorithm is built for image processing of polar microstructures. Hence, an experimental investigation of the influence of cutting tool geometry, depth of cut, and groove spacing of polar microstructures was conducted. There are transition points from which the patterns of surface generation of polar microstructures vary with the machining parameters. The optimization of machining parameters and determination of the optimized cutting strategy are undertaken in the ultra-precision machining of polar microstructures.

New Development in High Efficiency Deep Grinding

2012 ◽  
Author(s):  
Andre D. L. Batako ◽  
Valery V. Kuzin ◽  
Brian Rowe
Keyword(s):  
Machine Tool ◽  
High Efficiency ◽  
Machining Process ◽  
Depth Of Cut ◽  
Removal Rates ◽  
Workpiece Surface ◽  
New Development ◽  
Cutting Processes ◽  
Selection Of ◽  
Made In

High Efficiency Deep Grinding (HEDG) has been known to secure high removal rates in grinding processes at high wheel speed, relatively large depth of cut and moderately high work speed. High removal rates in HEDG are associated with very efficient grinding and secure very low specific energy comparable to conventional cutting processes. Though there exist HEDG-enabled machine tools, the wide spread of HEDG has been very limited due to the requirement for the machine tool and process design to ensure workpiece surface integrity. HEDG is an aggressive machining process that requires an adequate selection of grinding parameters in order to be successful within a given machine tool and workpiece configuration. This paper presents progress made in the development of a specialised HEDG machine. Results of HEDG processes obtained from the designed machine tool are presented to illustrate achievable high specific removal rates. Specific grinding energies are shown alongside with measured contact arc temperatures. An enhanced single-pole thermocouple technique was used to measure the actual contact temperatures in deep cutting. The performance of conventional wheels is depicted together with the performance of a CBN wheel obtained from actual industrial tests.

Wear Behavior of Carbide Inserts in Face Milling TA19 Alloy

2012 ◽  
Vol 426 ◽  
pp. 339-343 ◽  
Author(s):  
Qiu Lin Niu ◽  
X.J. Cai ◽  
Zhi Qiang Liu ◽  
Ming Chen ◽  
Qing Long An
Keyword(s):  
Titanium Alloy ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Aircraft Engine ◽  
Face Milling ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Crater Wear ◽  
Stable Conditions ◽  
Carbide Inserts

As a typical high strength material, titanium alloy Ti-6Al-2Sn-4Zr- 2Mo-0.1Si (TA19) is used to manufacturing the compressor power-brake of aircraft engine and the aircraft skin. All the machining experiments were carried out on a CNC-milling center under the stable conditions of cutting speed, feed rate, and depth of cut. The performance and wear mechanisms of coated- and uncoated carbide tools have been investigated in this paper to evaluate the machinability of TA19 in face milling. The three tools used were PVD-TiN+TiAlN, CVD-TiN+Al2O3+TiCN and uncoated carbide inserts. The results indicated that PVD coating had the best performance than other tool materials in milling titanium alloy TA19, and the cutting force and the wear value were the smallest than that for CVD-coated and uncoated tools. The failure types of PVD-, CVD- and uncoated inserts were the crater wear and micro tipping; the crater wear and tipping; tipping. Abrasive wear and adherent wear were the predominant mechanism of PVD-TiN+TiAlN carbide insert in face milling TA19 alloy. For CVD- and uncoated carbide, adherent wear was predominant.

OPTIMISING CUTTING PARAMETERS FOR HOT TURNING ON EN31 MATERIAL

2021 ◽  
Vol 5 (10) ◽  
Author(s):  
Prof. Hemant k. Baitule ◽  
Satish Rahangdale ◽  
Vaibhav Kamane ◽  
Saurabh Yende
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
Multiple Time ◽  
Turning Process ◽  
Workpiece Material ◽  
Hot Turning

In any type of machining process the surface roughness plays an important role. In these the product is judge on the basis of their (surface roughness) surface finish. In machining process there are four main cutting parameter i.e. cutting speed, feed rate, depth of cut, spindle speed. For obtaining good surface finish, we can use the hot turning process. In hot turning process we heat the workpiece material and perform turning process multiple time and obtain the reading. The taguchi method is design to perform an experiment and L18 experiment were performed. The result is analyzed by using the analysis of variance (ANOVA) method. The result Obtain by this method may be useful for many other researchers.

The Ledge Tool: A New Cutting Tool Insert

1985 ◽  
Vol 107 (2) ◽  
pp. 99-106 ◽  
Author(s):  
R. Komanduri ◽  
M. Lee
Keyword(s):  
Titanium Alloys ◽  
High Speed ◽  
Cutting Tool ◽  
Metal Removal ◽  
Face Milling ◽  
Cemented Carbide ◽  
Depth Of Cut ◽  
Peripheral Milling ◽  
Cemented Carbide Tool ◽  
Edge Wear

The salient features of a simple, wear-tolerant cemented carbide tool are described. Results are presented for high-speed machining (3 to 5 times the conventional speeds) of titanium alloys in turning and face milling. This tool, termed the ledge cutting tool, has a thin (0.015 to 0.050 in.) ledge which overhangs a small distance (0.015 to 0.060 in.) equal to the depth of cut desired. Such a design permits only a limited amount of flank wear (determined by the thickness of the ledge) but continues to perform for a long period of time as a result of wear-back of the ledge. Under optimum conditions, the wear-back occurs predominantly by microchipping. Because of geometric restrictions, the ledge tool is applicable only to straight cuts in turning, facing, and boring, and to face milling and some peripheral milling. Also, the maximum depth of cut is somewhat limited by the ledge configuration. In turning, cutting time on titanium alloys can be as long as ≈ 30 min. or more, and metal removal of ≈ 60 in.3 can be achieved on a single edge. Wear-back rates in face milling are about 2 to 3 times higher than in straight turning. The higher rates are attributed here to the interrupted nature of cutting in milling. Use of a grade of cemented carbide (e.g., C1 Grade) which is too tough or has too thick a ledge for a given application leads to excessive forces which can cause gross chipping of the ledge (rapid wear) and/or excessive deflection of the cutting tool with reduced depth of cut. Selection of a proper grade of carbide (e.g., Grades C2, C3, C4) for a given application results in uniform, low wear-back caused by microchipping. Because of the end cutting edge angle (though small, ≈ 1 deg) used, the ledge tool can generate a slight taper on very long parts; hence an N.C. tool offset may be necessary to compensate for wear-back. The ledge tool is found to give excellent finish (1 to 3 μm) in both turning and face milling. In general, conventional tooling with slight modifications can be used for ledge machining. The ledge tool can also be used for machining cast iron at very high speeds.

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