Experimental Study on High-Speed Milling of SiCf/SiC Composites with PCD and CVD Diamond Tools

Silicon carbide fiber reinforced silicon carbide ceramic matrix composite (SiCf/SiC composite) is characterized by a high strength-to-density ratio, high hardness, and high temperature resistance. However, due to the brittleness of the matrix material and the anisotropy of the reinforcing phase, it is a huge challenge for machining of the material. The milling method has advantages of a high material removal rate and applicability to complex surface geometry. However, no published literature on milling of SiCf/SiC composite has been found up to now. In this paper, high-speed milling of SiCf/SiC composites was carried out under dry conditions and cryogenic cooling using liquid nitrogen, respectively. Polycrystalline diamond (PCD) and chemical vapor deposition (CVD) diamond cutting tools were used for the milling work. The cutting performance of the two kinds of tools in high-speed milling of SiCf/SiC composites was studied. Tool failure modes and mechanisms were analyzed. The effects of the cooling approach on tool wear and machined surface quality were also investigated. The experimental results showed that under identical cutting parameters and cooling approaches, the PCD tool yielded better cutting performance in terms of a longer tool life and better surface quality than that of the CVD diamond tool. In dry machining, the failure modes of the CVD diamond tool were a large area of spalling on the rake face, edge chipping and severe tool nose fracture, whereas for the PCD tool, only a small area of spalling around the tool nose took place. Compared to the dry machining, the wear magnitudes of both PCD and CVD diamond tools were decreased in cryogenic machining. Additionally, the surface quality also showed significant improvements. This study indicates that the PCD tool is highly suitable for machining of SiCf/SiC composite, and that the cryogenic method can improve machining efficiency and surface quality.

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Effect of High Speed Milling Process Parameters on the Milling Force and Surface Topography of AM50A Magnesium Alloy

Xibei Gongye Daxue Xuebao/Journal of Northwestern Polytechnical University ◽

10.1051/jnwpu/20183610124 ◽

2018 ◽

Vol 36 (1) ◽

pp. 124-131

Author(s):

Hongji Zhang ◽

Yuanyuan Ge ◽

Hong Tang ◽

Yaoyao Shi ◽

Zengsheng Li

Keyword(s):

Magnesium Alloy ◽

Surface Quality ◽

High Speed ◽

Milling Process ◽

Spindle Speed ◽

Feed Speed ◽

Milling Force ◽

High Speed Milling ◽

Milling Parameters

Within the scope of high speed milling process parameters, analyzed and discussed the effects of spindle speed, feed rate, milling depth and milling width on milling forces in the process of high speed milling of AM50A magnesium alloy. At the same time, the influence of milling parameters on the surface roughness of AM50A magnesium alloy has been revealed by means of the measurement of surface roughness and surface micro topography. High speed milling experiments of AM50A magnesium alloy were carried out by factorial design. Form the analysis of experimental results, The milling parameters, which have significant influence on milling force in high speed milling of AM50A magnesium alloy, are milling depth, milling width and feed speed, and the nonlinear characteristics of milling force and milling parameters. The milling force decreases with the increase of spindle in the given mill parameters. For the effects of milling parameters on surface quality of the performance, in the milling depth and feeding speed under certain conditions with the spindle speed increases the surface quality of AM50A magnesium alloy becomes better with the feed speed increases the surface quality becomes poor. When the spindle speed is greater than 12000r/min, the milling depth is less than 0.2mm, and the feed speed is less than 400mm/min, the milling surface quality can be obtained easily.

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Wear mechanisms of PCD tool in high-speed milling of SiCp/Al composites

Optics and Precision Engineering ◽

10.3788/ope.20111912.2907 ◽

2011 ◽

Vol 19 (12) ◽

pp. 2907-2918 ◽

Cited By ~ 2

Author(s):

葛英飞 GE Ying-fei ◽

徐九华 XU Jiu-hua ◽

傅玉灿 FU Yu-can

Keyword(s):

Wear Mechanisms ◽

High Speed ◽

High Speed Milling ◽

Pcd Tool

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Study on High Speed Machining Strategies for Mold

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.591-593.468 ◽

2012 ◽

Vol 591-593 ◽

pp. 468-471

Author(s):

Yong Xia Liu ◽

Ru Shu Peng ◽

Qiang Cheng

Keyword(s):

Surface Roughness ◽

Surface Quality ◽

High Speed ◽

Intake Manifold ◽

High Speed Machining ◽

Machining Time ◽

High Speed Milling ◽

Tool Paths ◽

Nc Program ◽

Machining Strategies

The advantages and current problems for the application of high-speed machining technology in mold manufacturing are discussed. The requirements of mold high-speed machining for tool paths are summarized. Using the software of Cimatron E7.0，the NC program of the outer mold for a car engine’s V8 intake manifold is analyzed and optimized designed. Programming technology and optional of cutters have been introduced in detail. In the high speed milling stages, using the new cutters, the hardened mold can be machined to reach the required size, shape and surface roughness, and the machining time is reduced greatly. The method of making high speed NC template based on the software Cimatron E7.0. is introduced. Using this method, the maching efficiency is improved greatly, and the mold’ s surface quality better.

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High speed milling technological regimes, process condition and technological equipment condition influence on surface quality parameters of difficult to cut materials

10.4995/thesis/10251/164122 ◽

2021 ◽

Author(s):

Andris Logins

Keyword(s):

Surface Quality ◽

High Speed ◽

Process Condition ◽

Quality Parameters ◽

Technological Equipment ◽

High Speed Milling ◽

Technological Regimes

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Cutting force and its frequency spectrum characteristics in high speed milling of titanium alloy with a polycrystalline diamond tool

Journal of Zhejiang University SCIENCE A ◽

10.1631/jzus.a1000408 ◽

2011 ◽

Vol 12 (1) ◽

pp. 56-62 ◽

Cited By ~ 13

Author(s):

Peng Liu ◽

Jiu-hua Xu ◽

Yu-can Fu

Keyword(s):

Titanium Alloy ◽

Cutting Force ◽

Frequency Spectrum ◽

High Speed ◽

Diamond Tool ◽

Polycrystalline Diamond ◽

High Speed Milling ◽

Spectrum Characteristics

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Surface Quality of High Speed Milling of Silicon Carbide by Using Diamond Coated Tool

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.446-447.275 ◽

2013 ◽

Vol 446-447 ◽

pp. 275-278 ◽

Cited By ~ 1

Author(s):

Mohammad Iqbal ◽

Mohamed Konneh ◽

Ahmad Yasir Bin Md Said ◽

Azri Fadhlan Bin Mohd Zaini

Keyword(s):

Surface Roughness ◽

Silicon Carbide ◽

High Speed ◽

Cutting Parameters ◽

Machining Process ◽

Depth Of Cut ◽

Work Piece ◽

Model Interaction ◽

High Speed Milling ◽

Coated Tool

The high speed milling of silicon carbide was discussed by using flat end-mill 2 mm in diameter diamond coated tool. Ultra-precision high speed spindle attachment was used to achieve cutting tool rotation speed as high as 50,000 rpm. Special fixture was designed to minimize the chatter on work-piece surface during the machining process. Three cutting parameters were selected as independent variables of the experiments. They were spindle speed, depth of cut and feed rate. The arithmetic mean value of roughness (Ra) was measured on the work-piece surface as the response of the experiment. Result of the experiment shows that the value of surface roughness can be achieved as low as 0.150 μm. Statistical analysis was provided to study the significant of the model, interaction among the cutting parameters and their effects to the surface roughness value.

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Analysis of Surface Morphology in Work Hardening of High-Speed Milling Based on Dislocation Theory

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.373-375.2015 ◽

2013 ◽

Vol 373-375 ◽

pp. 2015-2018

Author(s):

Wen Jie Yang ◽

Su Yu Wang ◽

Yuan Chao Du ◽

Lin Lin Ma

Keyword(s):

Surface Quality ◽

Work Hardening ◽

High Speed ◽

Lattice Distortion ◽

Dislocation Theory ◽

Machined Surface ◽

High Speed Milling ◽

Forming Mechanism ◽

Machined Surface Quality ◽

Micro Morphology

Work hardening is an important index for the evaluation of the machined surface quality in high-speed milling. The morphology of work hardening can be visually observed by the metallographic pictures of high-speed milling gained from the scanning electron microscope which includes the lattice distortion and cracks etc. Forming mechanism of lattice distortion and micro crack of micro morphology under the workpiece surface is analyzed according to the dislocation theory; meanwhile, the effects on surface quality of the microstructure of the work hardening layer are discussed, which have important guiding significances on improving the surface quality and prolonging the service life of the parts.

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Prediction of cutting power and surface quality, and optimization of cutting parameters using new inference system in high-speed milling process

Advances in Manufacturing ◽

10.1007/s40436-020-00339-6 ◽

2021 ◽

Author(s):

Long-Hua Xu ◽

Chuan-Zhen Huang ◽

Jia-Hui Niu ◽

Jun Wang ◽

Han-Lian Liu ◽

...

Keyword(s):

Surface Quality ◽

High Speed ◽

Cutting Parameters ◽

Milling Process ◽

Inference System ◽

High Speed Milling ◽

Cutting Power ◽

Optimization Of Cutting Parameters

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Research on Cutting Performance in High-speed Milling of TC11 Titanium Alloy Using Self-propelled Rotary Milling Cutters

10.21203/rs.3.rs-205334/v1 ◽

2021 ◽

Author(s):

Yujiang Lu ◽

Tao Chen

Keyword(s):

Titanium Alloy ◽

Tool Wear ◽

Surface Quality ◽

Wear Mechanism ◽

High Speed ◽

Cutting Edge ◽

Machining Process ◽

High Speed Milling ◽

Tc11 Titanium Alloy ◽

Milling Forces

Abstract Titanium alloy materials, with excellent chemical and physical properties, are widely applied to the manufacture of key components in the aerospace industry. Nevertheless, its hard-to-machine characteristic causes various problems in the machining process, such as severe tool wear, difficulty to ensure good surface quality, etc. To achieve high efficiency and quality of machining titanium alloy materials, this paper conducted an experimental research on the high-speed milling of TC11 titanium alloy with self-propelled rotary milling cutters. In the work, the wear mechanism of self-propelled rotary milling cutters was explored, the influence of milling velocity was analyzed on the cutting process, and the variation laws were obtained of milling forces, chip morphology and machined surface quality with the milling length. The results showed that in the early and middle stages of milling, the insert coating peeled off evenly under the joint action of abrasive and adhesive wear mechanisms. As the milling length increased, the dense notches occurred on the cutting edge of the cutter, the wear mechanism converted gradually into fatigue wear, and furthermore coating started peeling off the cutting edge with the occurrence of thermal fatigue cracks on the insert. As the milling length was further extended, the milling forces tended to intensify, the chip deformation worsened, and the obvious cracks occurred at the bottom of chips. Moreover, the rise in milling velocity reduced the tool wear resistance, increased obviously the milling forces and the surface roughness.

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