scholarly journals Study on Cutting Chip in Milling GH4169 with Indexable Disc Cutter

Materials ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 3135
Author(s):  
Gensheng Li ◽  
Chao Xian ◽  
Hongmin Xin
Keyword(s):  
Chip Thickness ◽  
Cutting Parameters ◽  
Disc Cutter ◽  
Maximum Deviation ◽  
Feed Speed ◽  
Deviation Rate ◽  
Qualitative Relationship ◽  
Predicted Values ◽  
Deformation Coefficient ◽  
And Control

The study and control for chip have a significant impact on machining quality and productivity. In this paper, GH4169 was cut with an indexable disc milling cutter. The chips corresponding to each group of cutting parameters were collected, and the chip parameters (chip curl radius, chip thickness deformation coefficient, and chip width deformation coefficient) were measured. The qualitative relationship between the chip parameters and cutting parameters was studied. The quadratic polynomial models between chip parameters and cutting parameters were established and verified. The results showed that the chip parameters (chip curl radius, chip thickness deformation coefficient and chip width deformation coefficient) were negatively correlated with spindle speed; chip parameters were positively correlated with feed speed; chip parameters were positively correlated with cutting depth. The maximum deviation rate between measured values and predicted values for chip curl radius was 9.37%; the maximum deviation rate for cutting thickness deformation coefficient was 13.8%, and the maximum deviation rate of cutting width deformation coefficient was 7.86%. It can be seen that the established models are accurate. The models have guiding significance for chip control.

scholarly journals Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 854
Author(s):  
Muhammad Aamir ◽  
Khaled Giasin ◽  
Majid Tolouei-Rad ◽  
Israr Ud Din ◽  
Muhammad Imran Hanif ◽  
...  
Keyword(s):  
Feed Rate ◽  
Surface Defects ◽  
Thrust Force ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

Effects of Insert Nose Radius and Processing Cutting Parameter on the Surface Roughness of Aisi 316 Stainless Steel

2010 ◽  
Vol 447-448 ◽  
pp. 51-54
Author(s):  
Mohd Fazuri Abdullah ◽  
Muhammad Ilman Hakimi Chua Abdullah ◽  
Abu Bakar Sulong ◽  
Jaharah A. Ghani
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 316

The effects of different cutting parameters, insert nose radius, cutting speed and feed rates on the surface quality of the stainless steel to be use in medical application. Stainless steel AISI 316 had been machined with three different nose radiuses (0.4 mm 0.8 mm, and 1.2mm), three different cutting speeds (100, 130, 170 m/min) and feed rates (0.1, 0.125, 0.16 mm/rev) while depth of cut keep constant at (0.4 mm). It is seen that the insert nose radius, feed rates, and cutting speed have different effect on the surface roughness. The minimum average surface roughness (0.225µm) has been measured using the nose radius insert (1.2 mm) at lowest feed rate (0.1 mm/rev). The highest surface roughness (1.838µm) has been measured with nose radius insert (0.4 mm) at highest feed rate (0.16 mm/rev). The analysis of ANOVA showed the cutting speed is not dominant in processing for the fine surface finish compared with feed rate and nose radius. Conclusion, surface roughness is decreasing with decreasing of the feed rate. High nose radius produce better surface finish than small nose radius because of the maximum uncut chip thickness decreases with increase of nose radius.

Predictive Modeling of Nonlinear Regenerative Chatter via Measurement, Analysis, and Simulation

1999 ◽  
Author(s):  
J. R. Pratt ◽  
M. A. Davies ◽  
M. D. Kennedy ◽  
T. Kalmár-Nagy
Keyword(s):  
Cutting Force ◽  
Initial Conditions ◽  
Stability Boundary ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Computational Techniques ◽  
Regenerative Chatter ◽  
Stability Lobe ◽  
Measurement Analysis ◽  
On Chip

Abstract A single-degree-of-freedom active cutting fixture is employed to reveal and analyse the hysteretic nature of the lobed stability boundary in a simple machining experiment. Specifically, the seventh stability lobe of a regenerative cutting process is mapped using experimental, analytical, and computational techniques. Then, taking width of cut as a control parameter, the transition from stable cutting to chatter is observed experimentally. The cutting stability is found to possess a substantial hysteresis so that either stable or chattering tool motions can exist at the same nominal cutting parameters, depending on initial conditions. This behavior is predicted by applying nonlinear regenerative chatter theory to an empirical characterization of the cutting force dependence on chip thickness. Time-domain simulations that incorporate both the nonlinear cutting force dependence on chip thickness and the multiple-regenerative effect due to the tool leaving the cut are shown to agree both qualitatively and quantitatively with experiment.

Study on the Influence of Anisotropy on Cutting Performance of Aviation Aluminium Alloy 7050-T7451

2020 ◽  
Vol 990 ◽  
pp. 29-35
Author(s):  
Hui Wang ◽  
Ying Meng ◽  
Duo Duo Li ◽  
Xiu Li Fu ◽  
Qi Hang Shi
Keyword(s):  
Aluminium Alloy ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Performance ◽  
Rolled Sheet ◽  
Feed Speed ◽  
Aluminium Alloy 7050 ◽  
Degree Of Anisotropy ◽  
Forming Angle

Based on the hypocycloid theory, a highspeed orthogonal cutting simulation model was established. The cutting parameters (cutting speed, feed rate) and plane forming angle of the workpiece of aeronautical aluminium alloy 7050-T7451 pre-stretched rolled sheet were simulated and validated. The mapping relationship between cutting parameters, anisotropy and cutting performance was analyzed. The results show that the degree of anisotropy and the difficulty of material cutting are proportional to the forming angle, and the anisotropy decreases with the increase of cutting speed and the decrease of feed speed. Finally, the optimal cutting process range of aluminum alloy 7050-T7451 was obtained, which provides data support for highspeed cutting of anisotropic materials.

Supervisory Control of Drilling

1996 ◽  
Vol 118 (1) ◽  
pp. 10-19 ◽  
Author(s):  
R. J. Furness ◽  
A. Galip Ulsoy ◽  
C. L. Wu
Keyword(s):  
Process Control ◽  
Torque Control ◽  
Feed Speed ◽  
Machining Time ◽  
Control Approach ◽  
Drilling Operation ◽  
Control Functions ◽  
Control Concept ◽  
Supervisory Process ◽  
And Control

A supervisory process control approach to machining is presented in this paper, and demonstrated by application to a drilling operation. The supervisory process control concept incorporates optimization and control functions in a hierarchical structure. This approach utilizes feedback measurements to parameterize the constraints of a process optimization problem whose solution determines both strategies and references for process control. For this particular drilling operation, a three-phase strategy (utilizing a combination of feed, speed, and torque control) evolved due to inherent variation in constraint activity as a function of hole depth. A controller comparison study was conducted which demonstrates the advantages of this approach compared to (1) uncontrolled “conventional” drilling, (2) feed and speed controlled drilling, and (3) torque and speed controlled drilling. Benefits of reduced machining time, improved hole quality, and the elimination of tool breakage are demonstrated, and the potential economic impact is highlighted for an example production application.

The Predicted Model of Surface Roughness in Resharpening End-Mill for Tool Grinder

2006 ◽  
Vol 505-507 ◽  
pp. 523-528
Author(s):  
H.S. Lu ◽  
B.Y. Lee ◽  
C.T. Chung ◽  
Y.L. Liu
Keyword(s):  
Surface Roughness ◽  
Computer Program ◽  
Cutting Parameters ◽  
Training Data ◽  
Depth Of Cut ◽  
End Mill ◽  
Factors Affecting ◽  
Predicted Model ◽  
Predicted Values ◽  
Major Factors

This paper presents a predicted model of surface roughness of radial relief for resharpening end-mill. This model is constructed using a polynomial network. The major factors affecting grinding parameters are considered to be wheel spindle speed, feedrate, and grinding depth of cut. Experiments under specified conditions are deliberately designed and conducted to obtain the corresponding tested data for surface roughness that are used for training data of the proposed polynomial network. Consequently, a predicted model for surface roughness is established. Furthermore, a computer program in VB language is written based on this model. It can quickly calculate predicted values of surface roughness by simply inputting required cutting parameters. According to the experimental results, the developed polynomial network model shows high predicting capability on surface roughness of radial relief, and possesses promising potential in the application of predicting surface roughness in resharpening end-mill operation.

Experimental Study on Cutting Force and Cutting Power in High Feed Milling of Ti5Al5Mo5VCrFe

2016 ◽  
Vol 836-837 ◽  
pp. 88-93
Author(s):  
Hui Sun ◽  
Hu Xiao ◽  
Liang Li
Keyword(s):  
Cutting Force ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Rough Machining ◽  
Cutting Power ◽  
Actual Output ◽  
Calculation Results ◽  
High Feed ◽  
Coated Carbide ◽  
Carbide Inserts

In order to improve the rough machining efficiency of titanium alloy, experiments were carried out to investigate the influence of feed per tooth on cutting force and cutting power with index-able coated carbide inserts. The curves of cutting parameters, including cutting force and cutting power, were obtained by single factor test. The results showed that, as the feed per tooth increases, the cutting force increases, especially in the direction of cutting width. All forces almost changed linearly with the changing of feed, and the cutting force of feed direction was the smallest force among the three directions of cutting force. The analytical model of tangential cutting force in the x-y plane was established. By calculating average chip thickness and relationships between tangential cutting force and measurements of cutting force to predict the cutting power, the calculation results were accurate which compared with the actual output power of the machine tool.

Formation and Control of Cutting Direction Burr in Machining

2012 ◽  
Vol 443-444 ◽  
pp. 601-606 ◽  
Author(s):  
Gui Cheng Wang ◽  
Qin Feng Li ◽  
Hong Jie Pei ◽  
Hai Jun Qu ◽  
Yun Ming Zhu
Keyword(s):  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Geometric Parameters ◽  
Precision Machining ◽  
Effect Factors ◽  
Main Effect ◽  
And Control ◽  
Cutting Experiments ◽  
Cutting Direction

In this paper, the forming processes, main effect factors and change law of the cutting direction burr in orthogonal cutting have been studied and related theories are analyzed based on the cutting experiments. The result shows that the forming processes of cutting direction burr consist of normal cutting, flexure deformation of end surface of workpiece, plastic effect, continuous cutting and shear-break separating in orthogonal cutting. And a new phenomenon was found that cutting direction burr is formed with the shear-break separation of the chip and workpiece machined surfaces. In addition, the size of cutting-direction burr varies with workpiece materials, cutting parameters and geometric parameters of cutting tool. The study may be important science and practical value in order to control and reduce cutting burr in precision machining.

Design and Experimental Study of a Vespiary Exsector

2012 ◽  
Vol 468-471 ◽  
pp. 397-400
Author(s):  
Yan Hai Tang ◽  
Jin Bing Hu ◽  
Ling Yang ◽  
Pei Xiang He
Keyword(s):  
High Speed ◽  
Orthogonal Experiment ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Small Scale ◽  
Feed Speed ◽  
Revolution Speed ◽  
Significance Levels ◽  
Sealing Mechanism ◽  
Low Efficiency

The traditional removal method of a vespiary is labor-costing with characteristics of low efficiency and safety. According to the work high above the ground with hidden risk of the vespiary removal, a mechanical vespiary exsector was designed. The exsector is driven by a high speed motor, and the vespiary is removed by a cutting wire with high revolution speed. The cutting part can rotate 90 through drawing a pulling rope. A 2-layer sealing mechanism is operated through another pulling rope. The vespiary exsector has overall characteristics of small scale, light weight and good dexterity. Orthogonal experiment results show that factors of cutting speed and feed speed significantly contribute the width of cutting slot at the significance levels of 0.01 and 0.05 respectively, and the optimum cutting parameters are: cutting speed 10000rpm, feed speed 0.04m/s and diameter of the cutting wire 2mm.

Design of Machine Tool Setting and Parameter Optimization

2013 ◽  
Vol 706-708 ◽  
pp. 1132-1135
Author(s):  
Xiu Fen Xu
Keyword(s):  
Machine Tool ◽  
Optimization Design ◽  
Production Efficiency ◽  
Cutting Parameters ◽  
Economic Benefits ◽  
Parameters Optimization ◽  
Machining Process ◽  
Feed Speed ◽  
Processing Efficiency ◽  
Nc Milling

To solve the existing problems in the NC machining process, the optimization design of cutting parameters in NC milling machine with genetic algorithm. With the maximum production efficiency as the optimization objective, the spindle speed, feed speed, milling width, depth and other parameters as optimal variables, establishes the optimization mathematical model of machine tool. The optimization results show that: parameters optimization can significantly improve the processing efficiency, and bring economic benefits for enterprises

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