Experimental Investigation on Cutting Performance of Face Milling Cutter

2012 ◽  
Vol 217-219 ◽  
pp. 2133-2137
Author(s):  
Bing Yan ◽  
Yang Li ◽  
Wei Wang ◽  
Hao Feng
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Angle Effect ◽  
Axial Depth

The cutting tool geometry and cutting parameters have a great impact on cutting force, while cutting force is an important factor which affecting the tool life. High speed cutting experiments have shown that when slight axial depth of cut is adopted, rake angle effect on main cutting force significantly. When cutting aluminum alloy, the roughness of machined surface decrease with increasing tool rake angle. The axial depth of cut does not have a big influence on machined surface ’s roughness.

Cutting Force in High-Speed Face Milling AISI H13 Steel

2015 ◽  
Vol 667 ◽  
pp. 35-40
Author(s):  
Xiao Bin Cui ◽  
Jing Xia Guo ◽  
Xiao Yang Wang
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Depth Of Cut ◽  
H13 Steel ◽  
Aisi H13 Steel ◽  
Aisi H13 ◽  
Axial Depth

For the purpose of acquiring thorough understanding of the characteristics of cutting force in high and ultra-high-speed face milling of hardened steel, experimental investigations on face milling of AISI H13 steel (46-47 HRC) are conducted in the present study. The cutting speed of 1400 m/min, at which relatively low cutting force and relatively low surface roughness can be obtained at the same time, is considered as a critical value for both mechanical load and surface finish. The Taguchi method is applied to investigate the effects of cutting parameters on cutting force in different speed ranges (below and above 1400 m/min). In different speed ranges, the contribution order of the cutting parameters for the resultant cutting force is the same, namely axial depth of cut, cutting speed and feed per tooth. However, the contributions of cutting speed and feed per tooth increase substantially as the cutting speed surpasses 1400 m/min. Within the range of cutting parameters used in the present study, the optimum cutting conditions for the cutting force are cutting speed 200 m/min, feed per tooth 0.02 mm/tooth and axial depth of cut 0.1 mm.

SURFACE ROUGHNESS OF MAGNESIUM ALLOY AZ91D IN HIGH SPEED MILLING

2016 ◽  
Vol 78 (6-9) ◽  
Author(s):  
Mohd Shahfizal Ruslan ◽  
Kamal Othman ◽  
Jaharah A.Ghani ◽  
Mohd Shahir Kassim ◽  
Che Hassan Che Haron
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Parameters ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Polishing Process ◽  
High Speed Cutting ◽  
Radial Depth

Magnesium alloy is a material with a high strength to weight ratio and is suitable for various applications such as in automotive, aerospace, electronics, industrial, biomedical and sports. Most end products require a mirror-like finish, therefore, this paper will present how a mirror-like finishing can be achieved using a high speed face milling that is equivalent to the manual polishing process. The high speed cutting regime for magnesium alloy was studied at the range of 900-1400 m/min, and the feed rate for finishing at 0.03-0.09 mm/tooth. The surface roughness found for this range of cutting parameters were between 0.061-0.133 µm, which is less than the 0.5µm that can be obtained by manual polishing. Furthermore, from the S/N ratio plots, the optimum cutting condition for the surface roughness can be achieved at a cutting speed of 1100 m/min, feed rate 0.03 mm/tooth, axial depth of cut of 0.20 mm and radial depth of cut of 10 mm. From the experimental result the lowest surface roughness of 0.061µm was obtained at 900 m/min with the same conditions for other cutting parameters. This study revealed that by milling AZ91D at a high speed cutting, it is possible to eliminate the polishing process to achieve a mirror-like finishing.

Effects of Cutting Parameters on Chip Side-Curl Mechanisms and Variable Tool-Chip Contact in Turning

1999 ◽  
Author(s):  
A. K. Balaji ◽  
I. S. Jawahir
Keyword(s):  
High Speed ◽  
Cutting Parameters ◽  
Sem Analysis ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Turning Operations ◽  
Variable Friction ◽  
On Chip ◽  
Bar Turning

Abstract This paper presents the results of an investigative study on the chip side-curling mechanism and the associated variable tool-chip contact in turning operations. The effect of various cutting and tool geometry parameters such as depth of cut-nose radius ratio, feed, inclination angle, etc. on chip side-curling are established in a hierarchical manner. The importance of variable friction at the tool-chip interface along the developed length of the cutting edge is shown from the experimental observations of the tool-chip contact area using a SEM analysis. The significant influence of the radial cutting force component on the resultant chip side-curl is established using a high speed-filming analysis of comparative experiments in tube and bar turning operations.

Model-based sensitivity analysis of machining-induced residual stress under minimum quantity lubrication

2015 ◽  
Vol 231 (9) ◽  
pp. 1528-1541 ◽  
Author(s):  
Xia Ji ◽  
Steven Y Liang
Keyword(s):  
Residual Stress ◽  
Sensitivity Analysis ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Mixture Ratio ◽  
Minimum Quantity

This article presents a sensitivity analysis of residual stress based on the verified residual stress prediction model. The machining-induced residual stress is developed as a function of cutting parameters, tool geometry, material properties, and lubrication conditions. Based on the residual stress predictive model, the main effects of the cutting force, cutting temperature, and residual stress are quantitatively analyzed through the cosine amplitude method. The parametric study is carried out to investigate the effects of minimum quantity lubrication parameters, cutting parameters, and tool geometry on the cutting performances. Results manifest that the cutting force and residual stress are more sensitive to the heat transfer coefficient and the depth of cut, while the cutting temperature is more sensitive to the cutting speed. Large maximum compressive residual stress is obtained under a lower flow rate of minimum quantity lubrication, small depth of cut, and the proper air–oil mixture ratio. This research can support the controlling and optimization of residual stress in industrial engineering by strategically adjusting the application parameters of minimum quantity lubrication.

Investigation of Surface Characteristics and Chip Morphology in High Speed Cutting of Inconel718 Based on SHPB System

2019 ◽  
Author(s):  
Zengqiang Wang ◽  
Zhanfei Zhang ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Kunyang Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Surface Profile ◽  
Chip Morphology ◽  
Depth Of Cut ◽  
Machined Surface ◽  
High Speed Cutting

Abstract High speed cutting (HSC) technology has the characteristics of high material removal rates and high machining precision. In order to study the relationships between chip morphology and machining surface characteristic in high speed cutting of superalloy Inconel718. High-speed orthogonal cutting experiment are carried out by used a high speed cutting device based on split Hopkinson pressure bar (SHPB). The specimen surfaces and collected chips were then detected with optical microscope, scanning electron microscope and three-dimensional surface profile measuring instrument. The results show that within the experimental parameters (cutting speed from 8–16m/s, depth of cut 0.1–0.5mm), the obtained chips are sawtooth chips and periodic micro-ripple appear on the machined surface. With the cutting speed increases, machining surface roughness is decreases from 1.4 to 0.99μm, and the amplitude of periodic ripples also decreases. With the cutting depth increases, the machining surface roughness increases from 0.96 to 5.12μm and surface topography becomes worse. With the increase of cutting speed and depth of cut, the chips are transform from continues sawtooth to sawtooth fragment. By comparing the frequency of surface ripples and sawtooth chips, it is found that they are highly consistent.

Finite Element Simulation on High Speed Cutting of Hardened 45 Steel Based on ABAQUS

2013 ◽  
Vol 579-580 ◽  
pp. 202-207
Author(s):  
Guo He Li ◽  
Hou Jun Qi ◽  
Bing Yan
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Cutting Process ◽  
High Speed Cutting ◽  
Geometry Model ◽  
Element Simulation

For the high speed cutting process of hardened 45 steel (45HRC), a finite element simulation of cutting deformation, cutting force and cutting temperature is finished with the large general finite element software ABAQUS. Through the building of geometry model, material model and heat conduction model, also the determination of boundary conditions, separation rule and friction condition, a thermal mechanical coupling finite element model of high speed cutting for hardened 45 steel is built. The serrated chip, cutting force and cutting temperature can be predicted. The comparison of experiment and simulation shows the validity of the model. The influence of cutting parameters on cutting process is investigated by the simulation under different cutting depthes and rake angles. The results show that as the increase of rake angle, the segment degree, cutting force and cutting temperature decrease. But the segment degree, also the cutting force and cutting temperature increase with the increase of cutting depth. This study is useful for the selection of cutting parameters of hardened steel.

The Effects of Cutting Parameters to the Surface Roughness in High Speed Cutting of Micro-Milling Titanium Alloy Ti-6Al-4V

2020 ◽  
Vol 846 ◽  
pp. 133-138
Author(s):  
Gandjar Kiswanto ◽  
Adrian Mandala ◽  
Maulana Azmi ◽  
Tae Jo Ko
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Weight Reduction ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Depth Of Cut ◽  
High Speed Cutting ◽  
Micro Scale

Micro-milling offers high flexibility by producing complex 3D micro-scale products. Weight reduction are one of the optimizations of the product that can make it stronger and more efficient nowadays. Titanium are the most commonly used for micro-scale products especially in biomedical industries because of the biocompatibility properties. Titanium alloys offers high strength with low density and high corrosion resistance that is suitable for weight reduction. This study aims to investigate the influence of high speed cutting parameters to the surface roughness in micromilling of titanium alloy Ti-6Al-4V as high speed cutting offers more productivity since producing more cutting length in the same time. experiments are carried out by micromilling process with variations in high speed cutting parameters of spindle speed and feed rate with a constant depth of cut using a carbide cutting tool of with a diameter of 1 mm. The machining results in the form of a 4 mm slot with a depth as the same as depth of cut, which then measures its surface roughness. It was found that higher feed rate that is followed by higher spindle speed will produce better surface roughness.

Energy Cost Optimization in High Speed Hard Turning Using Simulated Annealing Algorithm

2015 ◽  
Vol 1115 ◽  
pp. 104-108
Author(s):  
Muataz Hazza F. Al Hazza ◽  
Erry Y.T. Adesta ◽  
Muhammad Hasibul Hasan ◽  
Norhashimah Shaffiar
Keyword(s):  
Simulated Annealing ◽  
Energy Cost ◽  
High Speed ◽  
Hard Turning ◽  
Simulated Annealing Algorithm ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Annealing Algorithm

Selecting the cutting conditions to optimize the economics of machining process as assessed by energy machining cost is essential. The aim of this research is to determine the optimum cutting parameters that minimize the energy cost needed for removing one cubic centimetre of material in High Speed Hard Turning (HSHT) process. To achieve that, a set of experimental machining data to cut hardened steel AISI 4340 was obtained with different ranges of cutting speed, feed rate, depth of cut and negative rake angle using mixed ceramic as a cutting tool. Regression models have been developed by using Box-Behnken design as a design of experiment. Then, the Simulated Annealing Algorithm (SAA) has been used to optimize the cutting parameters. The data collected was statistically modelled. The results show that the range of minimum energy cost to remove one cubic centimetre of material for the three techniques can be achieved in the range of 300 to 308 as a cutting speed, -12 for cutting rake angle, 0.125 as a feed rate and 0.15 as a depth of cut.

Effects of Cutting Conditions on the Machinability of Stainless Steel Formed by Laser Cladding

2013 ◽  
Vol 797 ◽  
pp. 166-171
Author(s):  
Bing Wang ◽  
Zhan Qiang Liu ◽  
Lun Chang Su ◽  
Lin Qing Zhang
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Force ◽  
Laser Cladding ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Corner Radius ◽  
1045 Steel

The paper investigates the effects of cutting conditions on the machinability of stainless steel coatings manufactured onto AISI 1045 steel by laser cladding technology. Two kinds of CBN (cubic boron nitride) tools with different corner radius and two different depths of cut were adopted in the experiments. Cutting force during machining, surface roughness and microhardness of machined surface were measured and analyzed. The results show that both the cutting force and surface roughness increase with the increase of depth of cut. When the other cutting parameters are identical, the surface roughness decreases with the increase of tools corner radius while the variations of different cutting force components present different tendencies. The microhardness of the machined surface and its varied gradient in the direction of depth of cut increase with the increase of tools corner radius. The experiment results will provide valuable suggestions for optimization of cutting performance for laser cladding coatings in order to obtain excellent surface quality.

Study of High-Speed Machining Parameters on Nickel-Based Alloy GH2132

2011 ◽  
Vol 189-193 ◽  
pp. 3142-3147 ◽  
Author(s):  
Dong Qiang Gao ◽  
Zhong Yan Li ◽  
Zhi Yun Mao
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Nickel Based Alloy

A model of stress and temperature field is established on nickel-based alloy cutting by finite element modeling and dynamic numerical simulating, and then combining high-speed machining test and orthogonality analysis method, the influence law of cutting parameters on the cutting force and tool wear has been researched, and the tool life and cutting force prediction model based on cutting parameters has been obtained. Finally, by genetic algorithm method cutting parameters are selected reasonably and optimized. The result shows that the bonding wear is main tool wear, and the influence of cutting speed on cutting force is smaller than feed per tooth and axial depth of cut.

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