An Analysis on Temperature & Surface Roughness during End Milling of Ti-6Al-4V Alloy

2014 ◽  
Vol 592-594 ◽  
pp. 38-42 ◽  
Author(s):  
S. Samsudeensadham ◽  
Vijayan Krishnaraj
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Metal Cutting ◽  
End Milling ◽  
Cutting Speed ◽  
Critical Issue ◽  
Vital Role ◽  
Effect Of Temperature ◽  
Regression Equations ◽  
Machined Surface

The heat produced in metal cutting process is one of the most critical issue in machining of titanium alloys. High temperature in metal cutting degrades the tool life, surface integrity, size accuracy and machining efficiency dramatically. The temperature generated during end milling of titanium alloy, has been measured using Thermo camera. Surface roughness plays a vital role in evaluating and measuring the quality of the machined surface. During the experiments, cutting speed and feed rate have been changed to analyse the effect of temperature and surface roughness. It is observed that cutting speed has the greater effect on temperature and surface roughness during end milling of titanium alloy. The regression equations generated have better fit which can be used for optimization.

scholarly journals Influence of Chatter of VMC Arising During End Milling Operation and Cutting Conditions on Quality of Machined Surface

1970 ◽  
Vol 2 (1) ◽  
Author(s):  
A.K.M.N. Amin, M.A. Rizal, and M. Razman
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Metal Removal ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
End Mill ◽  
Machined Surface ◽  
Operating Cycle ◽  
Wide Range

Machine tool chatter is a dynamic instability of the cutting process. Chatter results in poor part surface finish, damaged cutting tool, and an irritating and unacceptable noise. Exten¬sive research has been undertaken to study the mechanisms of chatter formation. Efforts have been also made to prevent the occurrence of chatter vibration. Even though some progress have been made, fundamental studies on the mechanics of metal cutting are necessary to achieve chatter free operation of CNC machine tools to maintain their smooth operating cycle. The same is also true for Vertical Machining Centres (VMC), which operate at high cutting speeds and are capable of offering high metal removal rates. The present work deals with the effect of work materials, cutting conditions and diameter of end mill cutters on the frequency-amplitude characteristics of chatter and on machined surface roughness. Vibration data were recorded using an experimental rig consisting of KISTLER 3-component dynamometer model 9257B, amplifier, scope meters and a PC.  Three different types of vibrations were observed. The first type was a low frequency vibration, associated with the interrupted nature of end mill operation. The second type of vibration was associated with the instability of the chip formation process and the third type was due to chatter. The frequency of the last type remained practically unchanged over a wide range of cutting speed.  It was further observed that chip-tool contact processes had considerable effect on the roughness of the machined surface.Key Words: Chatter, Cutting Conditions, Stable Cutting, Surface Roughness.

An Approach to Improve Cutting Performance in Micromilling of Titanium Alloy

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
Yunn-Shiuan Liao ◽  
Tsung-Hsien Li ◽  
Yi-Chen Liu
Keyword(s):  
Carbon Dioxide ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Liquid Carbon ◽  
Dry Cutting ◽  
Machined Surface ◽  
Liquid Carbon Dioxide

Abstract Application of liquid carbon dioxide to improve cutting performance in micro-end milling of Ti-6Al-4V titanium alloy was proposed in this study. It was found that the machined roughness decreased with the cutting speed as observed in the conventional cutting, when a 0.5 mm diameter end milling cutter was used in dry cutting. But, the tiny and shattered chips produced by the use of 0.3 mm diameter cutter could adhere on the machined surface and deteriorate surface finish, if the cutting speed was higher than 40 m/min. Cutting temperature was effectively decreased by applying liquid carbon dioxide during micromilling, which in turn reduced the amount of chips adhering on the machined surface and lowered flank wear. The surface roughness Ra at a cutting speed of 70 m/min was improved from 0.09 μm under dry cutting to 0.04 μm under the liquid carbon dioxide assisted cutting condition. And there were no flank wear and very few burrs left on the machined surface for the condition used in the experiment. The height of the burrs was only 25% of that under dry cutting. More, minimum quantity lubrication (MQL) was proposed to be applied together with the liquid carbon dioxide to enhance lubrication effect. It was noted that the machined surface roughness was further decreased by 15% as compared with that when the liquid carbon dioxide was applied alone. The height of burrs was reduced from 32 μm to 16 μm.

Experimental Research of Effective Cutting Speed Influence on Surface Roughness in Ball End Milling of C45 Material with Hardness 34 HRC

2014 ◽  
Vol 657 ◽  
pp. 53-57 ◽  
Author(s):  
Sándor Ravai Nagy ◽  
Ioan Paşca ◽  
Mircea Lobonțiu ◽  
Mihai Banica
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Experimental Research ◽  
Inclination Angle ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Speed ◽  
Cnc Machine Tools ◽  
Machined Surface ◽  
Ball End Milling

Machining of Complex Concave or Convex Surfaces Requires the Use of Ball End Milling Cutters. Obtaining the Expected Surface Quality Compete Various Technological Factors which should be Taken into Account. Following the Machining of the Surface with Different Inclination Angles between the Cutting Tool Axes and the Machined Surface, Significant Changes of the Surface Roughness have been Observed. Based on the Tests Performed, we can Determine the Range of the Tool Inclination Angle, which is the Best for the Surface Quality. we have also Made a Correlation between the Cutting Speeds, Inclination Angle of the Cutting Tool Toward the Machined Surface for an Obtained Surface Quality. the Presented Results are Based on Experimental Research in Industrial Conditions by Using CNC Machine Tools with 5 Axes. the Tests have been Performed on the C45 Material, Heat Treated to 34HRC.

Surface Integrity and Fatigue Property of a High Speed Milled Titanium Alloy

2008 ◽  
Vol 53-54 ◽  
pp. 305-310 ◽  
Author(s):  
Guo Sheng Geng ◽  
Jiu Hua Xu
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Work Hardening ◽  
High Speed ◽  
Cutting Speed ◽  
Fatigue Property ◽  
Machined Surface ◽  
Metallurgical Structure

Surface integrity has a great effect on the fatigue property of titanium alloy. The surface integrity and fatigue property of a high speed milled Ti-6.5Al-2Zr-1Mo-1V (TA15) titanium alloy were investigated in this research. The main objective of this paper is to study the influence of milling speed on the surface integraty and fatigue property of the machined part. The surface roughness, work hardening, metallurgical structure and residual stress of the machined surface were studied in a cutting speed range of from 50m/min to 300m/min. To verify the relationship between cutting speed and the surface integrity of machined surface, the fatigue property of titanium alloy specimens milled at four different cutting speeds ranging from 50 to 200m/min were compared at two stress levels. This research shows that the cutting speed has little effect on the work hardening, metallurgical structure and residual stress, but the surface roughness decreases with the increasing cutting speed. Therefore, increasing milling speed has a positive effect on the surface integrity and fatigue property of the machined surface.

The Investigation of Prediction Surface Roughness from Machining Forces in End Milling Processes

2011 ◽  
Vol 486 ◽  
pp. 91-94 ◽  
Author(s):  
Jabbar Abbas ◽  
Amin Al-Habaibeh ◽  
Dai Zhong Su
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Irregular Waves ◽  
Depth Of Cut ◽  
End Mill ◽  
Machined Surface ◽  
Machining Forces ◽  
Mill Cutter

Surface roughness is one of the most significant parameters to determine quality of machined parts. Surface roughness is defined as a group of irregular waves in the surface, measured in micrometers (μm). Many investigations have been performed to verify the relationship between surface roughness and cutting parameters such as cutting speed, feed rate and depth of cut. To predict the surface produced by end milling, surface roughness models have been developed in this paper using the machining forces by assuming the end mill cutter as a cantilever beam rigidly or semi- rigidly supported by tool holder. An Aluminium workpiece and solid carbide end mill tools are used in this work. Model to predict surface roughness has been developed. Close relationship between machined surface roughness and roughness predicted using the measured forces signals.

Investigating the Effect of Cutting Speed Variation on Surface Roughness of 7136 Aluminum Alloy in End Milling

2015 ◽  
Vol 809-810 ◽  
pp. 129-134 ◽  
Author(s):  
Alina Bianca Bonţiu Pop ◽  
Mircea Lobonţiu
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Metal Cutting ◽  
End Milling ◽  
Cutting Speed ◽  
Processing Parameters ◽  
Milling Process ◽  
Future Research ◽  
Cutting Depth ◽  
Speed Variation

Surface quality is affected by various processing parameters and inherent uncertainties of the metal cutting process. Therefore, the surface roughness anticipation becomes a real challenge for engineers and researchers. In previous researches [1] I have investigated the feed rate influence on surface roughness and manufacturing time reduction. The 7136 aluminum alloy was machined by end milling operation using standard tools for aluminum machining. The purpose of this paper is to identify by experiments the influence of cutting speed variation on surface roughness. The scientific contribution brought by this research is the improvement of the end milling process of 7136 aluminum alloy. This material is an aluminum alloy developed by Universal Alloy Corporation and is used in the aircraft industry to manufacture parts from extruded profiles. The research method used to solve the problem is experiment. A range of cutting speeds was used while the cutting depth and the feed per tooth were constrained per minimum and maximum requirements defined for the given cutting tool. The experiment was performed by using a 16 mm End milling cutter, holding two indexable cutting inserts. The machine used for the milling tests was a HAAS VF2 CNC. The surface roughness (response) was measured by using a portable surface roughness tester (TESA RUGOSURF 20 Portable Surface Finish Instrument). Following the experimental research, results were obtained which highlight the cutting speed influence on surface roughness. Based on these results we created roughness variation diagrams according to the cutting speed for each value of feed per tooth and cutting depth. The final results will be used as data for future research.

Optimization of Surface Roughness in End Milling of Titanium Alloy Ti-6Al-4V under the Influence of Magnetic Field from Permanents Magnets

2012 ◽  
Vol 576 ◽  
pp. 51-55 ◽  
Author(s):  
Syidatul Akma Sulaiman ◽  
A.K.M. Nurul Amin ◽  
M.D. Arif
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Permanent Magnets ◽  
End Milling ◽  
Desirability Function ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Central Composite

This paper presents the effect of cutting parameters on surface roughness in end milling of Titanium alloy Ti-6Al-4V under the influence of magnetic field from permanent magnets. Response Surface Methodology (RSM) with a small central composite design was used in developing the relationship between cutting speed, feed, and depth of cut, with surface roughness. In this experiment, three factors and five levels of central composite with 0.16817 alpha value was used as an approach to predict the surface roughness, in end milling of titanium alloy, with reasonable accuracy. The Design-Expert 6.0 software was applied to develop the surface roughness equation for the predictive model. The adequacy of the surface roughness model was validated to 95% by using ANOVA analysis. Finally, desirability function approach was used to determine the optimum possible surface roughness given the capabilities of the end machine.

Optimization of Surface Roughness in End Milling of Medium Carbon Steel under the Influence of Magnets Attached to the Machine Spindle

2012 ◽  
Vol 576 ◽  
pp. 115-118
Author(s):  
A.K.M. Nurul Amin ◽  
Syidatul Akma ◽  
Maizatul Akma ◽  
M.D. Arif
Keyword(s):  
Surface Roughness ◽  
Carbon Steel ◽  
Metal Cutting ◽  
Permanent Magnets ◽  
End Milling ◽  
Cutting Speed ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Medium Carbon

One of the major technological parameters in metal cutting is surface roughness. It is an unavoidable, and often, unwanted by-product of all machining operations, especially end milling. Surface roughness is directly related to product quality and performance, operation cost, machining accuracy, and chatter. Today’s stringent customer requirements demand machined parts with minimum (mirror finished) products. Hence, the prediction, modeling, and optimization of surface roughness is a quintessential concern in machining research and industrial endeavor. This research was undertaken in order to determine whether end milling of medium carbon steel performed using chosen ranges of cutting parameter and under magnetic field generated by permanent magnets could effectively improve surface roughness. A small central composite design with five levels and an alpha value of 1.4142, in Response Surface Methodology, was used in developing the relationship between cutting speed, feed, and depth of cut, with surface roughness. Design-Expert 6.0 software was utilized to develop the quadratic empirical mathematical model for surface roughness. The experiments were performed under two different conditions. The first condition was cutting under normal conditions, while the other one was cutting under the application of magnetic fields from two permanent magnets. Medium carbon steel was used as the work material. The resultant average surface roughness was found to be reduced by a maximum of 59% due to magnet application.

scholarly journals Experimental Study on Surface Integrity of Titanium Alloy Ti6Al4V by Ball End Milling

2018 ◽  
Vol 14 (1) ◽  
pp. 115-121 ◽  
Author(s):  
Pun Krishna Kaway ◽  
Xueping Zhang
Keyword(s):  
Titanium Alloy ◽  
Surface Integrity ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Ball End Milling ◽  
Titanium Alloy Ti6al4v ◽  
Cutting Speeds

Titanium alloy, Ti6Al4V, has been widely used in aerospace, automotive, biomedical, and chemical industries due to its exceptional strength to weight ratio, high temperature performance, and corrosion resistance. However, machinability of Ti6Al4V is poor due to high strength at elevated temperatures, low modulus, and low thermal conductivity. Poor machinability of Ti6Al4V deteriorates the surface integrity of the machined surface. Poor surface integrity causes high machining cost, surface defects, initiate cracks, and premature failure of the machined surface. Thus, it is indispensable to obtain better surface integrity when machining titanium alloy Ti6Al4V. Cutting parameters such as cutting speed, feed rate, and depth of cut have significant effect on the surface integrity when machining titanium alloy Ti6Al4V. Hence, this study investigates surface integrity of Ti6Al4V by ball end milling at different cutting speeds, feed rates, and depth of cuts. Microstructure of subsurface is studied at different cutting speeds, feed rates, and depth of cuts. The results show that the depth of deformation of subsurface increases with increase in the cutting speed, feed rate, and depth of cut. Journal of the Institute of Engineering, 2018, 14(1): 115-121

scholarly journals Effect of Different Cooling Strategies on Surface Quality and Power Consumption in Finishing End Milling of Stainless Steel 316

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 903
Author(s):  
Adel T. Abbas ◽  
Saqib Anwar ◽  
Elshaimaa Abdelnasser ◽  
Monis Luqman ◽  
Jaber E. Abu Qudeiri ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Surface Quality ◽  
Process Parameters ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Machined Surface ◽  
Cooling Strategies ◽  
Dry Conditions

In this paper, an experimental investigation into the machinability of AISI 316 alloy during finishing end milling operation under different cooling conditions and with varying process parameters is presented. Three environmental-friendly cooling strategies were utilized, namely, dry, minimal quantity lubrication (MQL) and MQL with nanoparticles (Al2O3), and the variable process parameters were cutting speed and feed rate. Power consumption and surface quality were utilized as the machining responses to characterize the process performance. Surface quality was examined by evaluating the final surface roughness and surface integrity of the machined surface. The results revealed a reduction in power consumption when MQL and MQL + Al2O3 strategies were applied compared to the dry case by averages of 4.7% and 8.6%, respectively. Besides, a considerable reduction in the surface roughness was noticed with average values of 40% and 44% for MQL and MQL + Al2O3 strategies, respectively, when compared to the dry condition. At the same time, the reduction in generated surface roughness obtained by using MQL + Al2O3 condition was marginal (5.9%) compared with using MQL condition. Moreover, the results showed that the improvement obtained in the surface quality when using MQL and MQL + Al2O3 coolants increased at higher cutting speed and feed rate, and thus, higher productivity can be achieved without deteriorating final surface quality, compared to dry conditions. From scanning electron microscope (SEM) analysis, debris, furrows, plastic deformation irregular friction marks, and bores were found in the surface texture when machining under dry conditions. A slight smoother surface with a nano-polishing effect was found in the case of MQL + Al2O3 compared to the MQL and dry cooling strategies. This proves the effectiveness of lubricant with nanoparticles in reducing the friction and thermal damages on the machined surface as the friction marks were still observed when machining with MQL comparable with the case of MQL + Al2O3.

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