Influence of the Temperature and Mechanical Stresses Generated by Milling Process in Machined Part Surfaces on their Accuracy

2013 ◽  
Vol 371 ◽  
pp. 59-63 ◽  
Author(s):  
Nicolae Catalin Tampu ◽  
Maria Crina Radu ◽  
Bogdan Chirita
Keyword(s):  
Residual Stress ◽  
Plastic Strain ◽  
Surface Quality ◽  
Cutting Parameters ◽  
Milling Process ◽  
Mechanical Stresses ◽  
Surface Generation ◽  
Work Piece ◽  
Stress Distributions ◽  
Surface Deviations

Surface generation by milling process involves the occurrence of some complex effects that affect surface quality. The most important effects of the milling on the generated surface are heating, plastic strain and residual stress. The aim of the present research is to analyze the influence of the work piece temperatures and residual stress distributions generated by milling in the machined surfaces on its accuracy. Two types of materials and different cutting parameters have been used in order to determine the above mentioned connection. The obtained results show that the temperature and residual stress generated by milling influences the surface deviations from flatness.

Experimental investigation of the influence of cutting parameters on surface quality and on the special characteristics of micro-milled surfaces of hardened steels

2021 ◽  
pp. 095440622110130
Author(s):  
Barnabás Zoltán Balázs ◽  
Márton Takács
Keyword(s):  
Surface Quality ◽  
Surface Profile ◽  
Cutting Parameters ◽  
Relevant Information ◽  
Milling Process ◽  
Micro Milling ◽  
Machined Surface ◽  
Analysis Of Dynamics ◽  
Five Axis ◽  
Coated Carbide

Micro-milling is one of the most essential technologies to produce micro components, but due to the size effect, it has many special characteristics and challenges. The process can be characterised by strong vibrations, relatively large run-out and tool deformation, which directly affects the quality of the machined surface. This paper deals with a detailed investigation of the influence of cutting parameters on surface roughness and on the special characteristics of micro-milled surfaces. Several systematic series of experiments were carried out and analysed in detail. A five-axis micromachining centre and a two fluted, coated carbide micro-milling tool with a diameter of 500 µm were used for the tests. The experiments were conducted on AISI H13 hot-work tool steel and Böhler M303 martensitic corrosion resistance steel with a hardness of 50 HRC in order to gain relevant information of machining characteristics of potential materials of micro-injection moulding tools. The effect of the cutting parameters on the surface quality and on the ratio of Rz/ Ra was investigated in a comprehensive cutting parameter range. ANOVA was used for the statistical evaluation. A novel method is presented, which allows a detailed analysis of the surface profile and repetitions, and identify the frequencies that create the characteristic profile of the surface. The procedure establishes a connection between the frequencies obtained during the analysis of dynamics (forces, vibrations) of the micro-milling process and the characterising repetitions and frequencies of the surface.

Research of Simulation Technology in Low-Stress Machining on Tooth Surface of Spiral Bevel Gears Used in Aviation Industry

2011 ◽  
Vol 86 ◽  
pp. 688-691
Author(s):  
Yan Zhong Wang ◽  
Yan Yan Chen ◽  
Xiao Han ◽  
Lin Feng Wu ◽  
Hong Zeng
Keyword(s):  
Cutting Parameters ◽  
Effect Study ◽  
Milling Process ◽  
Tooth Surface ◽  
Aviation Industry ◽  
Stress Distributions ◽  
Element Analysis ◽  
3 Dimensional ◽  
Real Size ◽  
Spiral Bevel

This paper had 3-dimensional models of a spiral bevel gear and a cutter in real size assembled in accordance with the milling process and transformed them into the finite element analysis (FEA) code. Then several researches on simulation methods of this milling system had been conducted, and stress distributions of gear surface after processing under different cutting conditions was given out, based on which a cause-effect study was carried out about the correlation between cutting parameters and the stress distribution, leading to methods of maintaining a low-stress condition during manufacturing.

A Study of Cutting Strategy in Single-Point Diamond Turning of Micro V-Groove Patterns on Precision Roller Drums

2014 ◽  
Vol 625 ◽  
pp. 742-747
Author(s):  
C.H. Mak ◽  
C.F. Cheung ◽  
M.J. Ren ◽  
L.B. Kong ◽  
S. To
Keyword(s):  
Surface Quality ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Surface Generation ◽  
Depth Of Cut ◽  
Tool Paths ◽  
Cutting Strategy ◽  
Groove Pattern

This paper presents a study of cutting strategies on the surface generation in single-point diamond turning of micro V-groove patterns on precision roller drums. An aluminium precision roller drum with a diameter 250mm and 100 long was diamond turned with a V-groove pattern. A series of cutting experiments were designed to study the effect of the variation of various cutting parameters and cutting tool paths on the surface quality in diamond turning of the precision roller drum. The parameters under investigation included the depth of cut, number of steps and the depth for each cut when diamond turning V-grooves on the cylindrical surface of a workpiece. The measurement result indicates that the surface quality of V-grooves machined on the precision roller drums is affected by cutting strategies. The optimal cutting strategy for machining a V-groove pattern on a precision drum with 5µm depth was obtained.

INVESTIGATION OF SURFACE INTEGRITY DURING TURNING INCONEL 718

2017 ◽  
Vol 41 (3) ◽  
pp. 387-394 ◽  
Author(s):  
M. Anthony Xavior ◽  
M. Manohar ◽  
Mahesh Madhukar Patil ◽  
P. Jeyapandiarajan
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Surface Quality ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Research Work ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Minimum Residual ◽  
Major Surface

Surface roughness and residual stress are considered to be major surface integrity issues that directly affect the quality and life of the components. The current research work highlights surface quality and residual stresses induced while machining Inconel 718 with a range of cutting parameters and cutting environments. Further, the study aimed to determine the optimal parameters/conditions in terms of cutting speeds, tool materials and cutting conditions to achieve better surface quality and minimum residual stress values. Minimum quantity lubrication resulted in minimum residual values for all cutting inserts and cutting velocities. The minimum surface roughness was obtained while machining at 100 m/min using a carbide insert under flood cooling condition.

Evaluation of Surface Quality and Signal Characteristics in Milling Process of Al7075-T651

2017 ◽  
Vol 737 ◽  
pp. 95-100
Author(s):  
M.C. Hwang ◽  
Joon Young Koo ◽  
Yong Ki Choi ◽  
Hyun Jung Kim ◽  
Jeong Suk Kim
Keyword(s):  
Aluminum Alloys ◽  
Surface Quality ◽  
Cutting Parameters ◽  
Milling Process ◽  
Signal Frequency ◽  
Burr Formation ◽  
Machined Surface ◽  
Specific Strength ◽  
Multiple Sensors ◽  
Signal Characteristics

Recently, as the automotive and aerospace industry research has focused one weight lightening, the use of functional aluminum alloys has been increasing. Aluminum alloys are effective materials because of their high specific strength and high stiffness ratio. However, machining deformation and heat deflection can occur depending on the machining type. Owing to these difficult-to-cut characteristics, it is necessary to monitor the machined surface quality of aluminum alloys. In this paper, we study the correlation between surface quality, namely burr formation and surface roughness, related to cutting parameters and signals obtained from multiple sensors. The output signals are measured by an acoustic emission (AE) sensor and an accelerometer and are analyzed in the signal frequency domain. By using the wavelet transform of analyzed signals, we determine the correlation between surface quality and signals. Based on this investigation, a surface quality monitoring system can be suggested.

Residual Stress Profile of Ultra High Strength Low Alloy Steel Induced by High Speed Milling Process

2013 ◽  
Vol 658 ◽  
pp. 188-193
Author(s):  
Kun Qiu ◽  
Zhen Hai Long
Keyword(s):  
Residual Stress ◽  
Compressive Stress ◽  
High Speed ◽  
High Strength ◽  
Cutting Parameters ◽  
Milling Process ◽  
Depth Of Cut ◽  
Stress Profile ◽  
Low Alloy Steel ◽  
Residual Stress Profile

In order to improve the surface quality of ultra high strength low alloy steel work-pieces produced by high-speed face milling process, 23-1 factorial design experiment was con-ducted and the residual stress profiles within the surface and subsurface layer of work-pieces were measured. Corresponding empirical models for the residual stress profile were presented and the effects of cutting parameters (cutting velocity, feed per tooth, depth of cut) on characteristics of the residual stress profile were studied. Results show that: with the range of cutting parameters tested, the compressive residual stress profile would be induced below the work-pieces’ surfaces machined by high speed face milling process. Feed per tooth has the critical influence on the characteristics of the compressive stress profile, and the mechanism of residual stress generation will be different when feed per tooth changes in high speed machining process. To obtain higher compressive stress and deeper compressive stress profile depth, larger feed rate and depth of cut are required.

An Experimental Study of the Effect of Cutting Parameters on Micro Milling Process

2012 ◽  
Vol 565 ◽  
pp. 558-563 ◽  
Author(s):  
Bing Wu ◽  
Huai Zhong Li ◽  
Jun Wang ◽  
Xiu Bing Jing
Keyword(s):  
Experimental Study ◽  
Surface Quality ◽  
Significant Influence ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Milling Process ◽  
Micro Milling ◽  
Material Hardness ◽  
Tool Diameter

In micro milling, cutting parameters such as feed per tooth and cutting speed are found to have significant influence on cutting forces and surface quality. To address these issues, an experimental study of micro milling with three types of metal material (steel, brass and aluminium alloy) is conducted. The experiment setup and cutting conditions are described; the experiment results are presented with a discussion of the influence of various cutting parameters such as feed per tooth and tool diameter. These results are used to provide strategies to optimise cutting parameters and achieve better surface quality with the concern of tool diameter and material hardness when micro milling selected materials.

scholarly journals Milling of an Al/CFRP Sandwich Construction with Non-Coated and TiAlN-Coated Tools

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3763
Author(s):  
Elżbieta Doluk ◽  
Anna Rudawska ◽  
Józef Kuczmaszewski ◽  
Paweł Pieśko
Keyword(s):  
Cutting Force ◽  
Surface Quality ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Helix Angle ◽  
Milling Process ◽  
Tialn Coating ◽  
Sandwich Construction ◽  
Coated Tools ◽  
Carbon Fibre Reinforced Polymer

In this study, the effect of cutting parameters on the quality of an Al/CFRP sandwich structure (aluminium alloy–carbon fibre reinforced polymer) after milling with uncoated and TiAlN-coated tools was examined. The results of the cutting force were also investigated. The research was conducted in a VMC 800 HS vertical machining centre with a variable cutting speed and feed. The milling process was carried out using a non-coated, two-blade carbide milling cutter with a 35° helix angle and an analogous tool with a TiAlN coating. The surface quality was characterised in terms of the height deviation, which is one of the shape deviations after machining hybrid materials. The research showed that the maximum (77.60 µm) and minimum (1.78 µm) values of the height deviations were obtained using the tool with a TiAlN coating. It was found that the tested factors had significant effects on the height deviation, where the feed had the greatest influence and the cutting speed had the lowest influence on the surface quality. The tested factors were not statistically significant in terms of the cutting force.

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