Reducing Tool Wear in CNC End Milling Operation Using Progressive Feed Rate

2014 ◽  
Vol 592-594 ◽  
pp. 716-723
Author(s):  
K.S. Badrinathan ◽  
L. Karunamoorthy
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Milling Operation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Cnc End Milling

This study focuses on the effect of cutting parameters on the tool wear in a CNC end milling operation. Major factors which influence the tool wear are spindle speed, feed rate and depth of cut. Conventionally constant feed rate is used. In this work a concept of progressive feed rate is introduced. AISI 1045 steel has been chosen as it is widely used in manufacturing. Design of Experiments (DOE) technique was adopted to conduct the experiments. Experiments were conducted for both the existing and the proposed feed rate method and the tool wear was compared. A statistical model was developed using Design Expert software. The predicted values were compared with the experimental values and were found to be in close agreement. The model adequacy was checked using ANOVA technique.

FEM Simulation of Machining AISI 1045 Steel Using Driven Rotary Tool

2015 ◽  
Vol 758 ◽  
pp. 77-82 ◽  
Author(s):  
Yanuar Burhannudin ◽  
Suryadiwansa Harun ◽  
Gusri Akhyar Ibrahim
Keyword(s):  
Feed Rate ◽  
Fem Simulation ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Rotary Tool ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Simulation Results ◽  
1045 Steel

This study investigates the influences of driven rotary tool (DRT) on temperatures and forces when turning AISI 1045 steel. A set of cutting conditions was used in FE simulations to predict cutting force, stresses and temperatures developed at around the edge of tool. The material cutting speed ranges were set between 20 and 250 m min-1. The rotary tool speed were 0 and 100 rpm.. The feed rate and the depth of cut were set constant. Simulation results provided the predicted cutting distribution of temperatures and stresses at the chip and work piece.

scholarly journals Analyzing the Effect of Machining Parameters Setting to the Surface Roughness during End Milling of CFRP-Aluminium Composite Laminates

2016 ◽  
Vol 2016 ◽  
pp. 1-9 ◽  
Author(s):  
M. Nurhaniza ◽  
M. K. A. M. Ariffin ◽  
F. Mustapha ◽  
B. T. H. T. Baharudin
Keyword(s):  
Surface Quality ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Optimal Cutting Parameters ◽  
Cnc End Milling

The quality of the machining is measured from surface finished and it is considered as the most important aspect in composite machining. An appropriate and optimum machining parameters setting is crucial during machining operation in order to enhance the surface quality. The objective of this research is to analyze the effect of machining parameters on the surface quality of CFRP-Aluminium in CNC end milling operation with PCD tool. The milling parameters evaluated are spindle speed, feed rate, and depth of cut. The L9 Taguchi orthogonal arrays, signal-to-noise (S/N) ratio, and analysis of variance (ANOVA) are employed to analyze the effect of these cutting parameters. The analysis of the results indicates that the optimal cutting parameters combination for good surface finish is high cutting speed, low feed rate, and low depth of cut.

scholarly journals Effect of Cutting Parameters on Tool-Chip Interface Temperature in an Orthogonal Turning Process

2014 ◽  
Vol 903 ◽  
pp. 21-26 ◽  
Author(s):  
Shamsuddin Sulaiman ◽  
Amir Roshan ◽  
Soroosh Borazjani
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Interface Temperature ◽  
Machined Surface ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

The aim of this paper is to investigate the effect of cutting speed and uncut chip thickness on cutting performance. A Finite Element Method (FEM) based on the ABAQUS explicit software which involves Johnson-Cook material mode and Coulombs friction law was used to simulate of High Speed Machining (HSM) of AISI 1045 steel. In this simulation work, feed rate ranging from 0.05 mm/rev to 0.13 mm/rev and cutting speed ranging from 200 m/min to 600 m/min at three different cutting speeds were investigated. From the simulation results it was observed that increasing feed rate and cutting speed lead to increase temperature and stress distribution at tool/chip interface. The results obtained from this study are highly essential to predict machining induced residual stresses and thermo-mechanical deformation related properties on the machined surface.

scholarly journals Experimental Design and Data collection of a finishing end milling operation of AISI 1045 steel

Data in Brief ◽  
2016 ◽  
Vol 6 ◽  
pp. 609-613 ◽  
Author(s):  
Luiz Gustavo Dias Lopes ◽  
Tarcísio Gonçalves de Brito ◽  
Anderson Paulo de Paiva ◽  
Rogério Santana Peruchi ◽  
Pedro Paulo Balestrassi
Keyword(s):  
Experimental Design ◽  
Data Collection ◽  
End Milling ◽  
Milling Operation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

scholarly journals Influence of Cutting Parameters on Chatter and Tool Wear During End Milling of Stainless Steel Conducted on VMC

1970 ◽  
Vol 3 (2) ◽  
Author(s):  
A.K.M.N. AMIN, M. IMRAN AND M. ARIF
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Surface Finish ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Wear Intensity ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Milling Operation

Stainless steels are a group of difficult to machine work materials. The difficulty in machining stainless steels is manifested in high contact length and stresses, formation of serrated chips and development of chatter resulting in high tool wear rates and poor machined surface finish. The paper focuses on the performance of TiN coated-carbide inserts in machining stainless steel specimens in end milling operation performed on vertical machining centre (VMC). The performance of the tool is evaluated from the point of view of its wear intensity, mechanism of failure and generation and effect of chatter on tool wear and vice versa. The investigations were aimed at determining the effect of cutting parameters, specifically cutting speed, feed and depth of cut, on chatter amplitude, tool wear rate, mechanism of tool wear and using these data and machined surface roughness values from previous work to come up with recommended values of cutting parameters for semi-finish and finish end milling operation of stainless steel work materials. For recording vibration signals a dual channel portable signal analyzers was used and the signals were analyzed using Pulse Multi-analyzer version 4.2 software. Tool wear was measured using an optical microscope with digital readout capabilities along 3 axes. The tool wear mechanisms were studied under a scanning electron microscope (SEM). Results of the investigation show that acceleration amplitudes generally increase with cutting speed and the magnitude of tool flank wears. It has been also found that an increase in feed and depth of cut leads to higher acceleration amplitudes. The most common wear mechanisms observed during machining of stainless steel are attrition, micro and macro chipping of the tool at lower cutting speeds, and diffusion and mechanical failures due to intensive chatter at higher speeds. It has been also established that stable cutting speeds with relatively low tool wear intensity and satisfactory machined surface finish can be achieved through proper selection of cutting parameters. A table of recommended cutting conditions has been developed for almost chatter free machining with low tool wear intensity and satisfactory surface finish. Key Words: Vertical Machining Centre, Machinability, Chatter, Cutting, Tool life.

Prediction of Tool Wear Mechanisms in Face Milling AISI 1045 Steel

2011 ◽  
Vol 21 (6) ◽  
pp. 797-808 ◽  
Author(s):  
Patricia Muñoz-Escalona ◽  
Nayarit Díaz ◽  
Zulay Cassier
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
Face Milling ◽  
Tool Wear Mechanisms ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Wear Characteristic and Life of Al2O3/(W,Ti)C Ceramic Tool in Turning Iron-Based P/M Composites

2010 ◽  
Vol 26-28 ◽  
pp. 1052-1055
Author(s):  
Li Fa Han ◽  
Sheng Guan Qu
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Empirical Model ◽  
Feed Rate ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Ceramic Tool ◽  
Iron Based

The wear characteristics and life of Al2O3/(W,Ti)C ceramic tool in turning NbCp-reinforced iron-based P/M composites was investigated. Experimental results indicate that cutting parameters have an influence on tool wear, among which cutting speed and depth of cut seem to be more prominent. The maximum flank wear rapidly increases as the increase in cutting speed and depth of cut. While, it increases gradually as the decrease in feed rate. Meanwhile, an empirical model of tool life is established, from which the influence of cutting speed and depth of cut on tool life is far greater than that of feed rate. Also from the empirical model, the preferable range of cutting parameters was obtained.

Experimental Investigation on the Effect of Tool Geometry and Cutting Conditions Using Tool Wear Prediction Model for End Milling Process

2014 ◽  
Vol 13 (01) ◽  
pp. 41-54 ◽  
Author(s):  
S. Kalidass ◽  
P. Palanisamy
Keyword(s):  
Tool Wear ◽  
End Milling ◽  
Cutting Parameters ◽  
304 Stainless Steel ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cutting Condition ◽  
Machining Parameter

Tool wear of a cutting tool has a significant impact on the tool life and surface quality of the finished product. Tool wear is influenced by many factors such as cutting parameters, tool geometry, coating type, work piece material, chatter, and cutting condition. In the present work, the design of experiments (DOE) technique has been used for four factors at five levels to conduct experiments. Tool wear is taken as the response variable measured during end milling, while helix angle, spindle speed, feed and depth of cut are taken as the input parameters. The material and tool selected for this study are AISI 304 stainless steel and uncoated solid carbide end mill cutter respectively. The tool wear was measured using tool maker's microscope. The experimental values are used in six sigma software for finding the coefficients to develop the regression model. The direct and interaction effect of the machining parameter with tool wear were analyzed using contour graphs, which helped to select process parameters for reducing tool wear and also ensure quality of milling.

scholarly journals Experimental Investigation on Surface Roughness and Tool Wear in Dry Machining of TiC Reinforced Aluminium LM6 Composite

2013 ◽  
Vol 773-774 ◽  
pp. 339-347 ◽  
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Carbide Tool ◽  
Dry Machining ◽  
Workpiece Surface ◽  
High Cutting Speed

With increasing quantities of applications of Metal Matrix Composites (MMCs), the machinablity of these materials has become important for investigation. This paper presents an investigation of surface roughness and tool wear in dry machining of aluminium LM6-TiC composite using uncoated carbide tool. The experiments carried out consisted of different cutting models based on combination of cutting speed, feed rate and depth of cut as the parameters of cutting process. The cutting models designed based on the Design of Experiment Response Surface Methodology. The objective of this research is finding the optimum cutting parameters based on workpiece surface roughness and cutting tool wear. The results indicated that the optimum workpiece surface roughness was found at high cutting speed of 250 m min-1 with various feed rate within range of 0.05 to 0.2 mm rev-1, and depth of cut within range of 0.5 to 1.5 mm. Turning operation at high cutting speed of 250 m min-1 produced faster tool wear as compared to low cutting speed of 175 m min-1 and 100 m min-1. The wear minimum (VB = 42 μm ) was found at cutting speed of 100 m min-1, feet rate of 0.2 mm rev-1, and depth of cut of 1.0 mm until the length of cut reached 4050 mm. Based on the results of the workpiece surface roughness and the tool flank wear, recommended that turning of LM6 aluminium with 2 wt % TiC composite using uncoated carbide tool should be carried out at cutting speed higher than 175 m min-1 but at feed rate of less than 0.05 mm rev-1 and depth of cut less than 1.0 mm.

Research on the Modeling and Experimenting of Burr Formation Process in Double-Edged Micro-Plat End Milling Operation

2013 ◽  
Vol 770 ◽  
pp. 248-252 ◽  
Author(s):  
Ni Chen ◽  
Ming Jun Chen ◽  
Hai Bo Ni ◽  
Ning He ◽  
Zhan Qiang Liu
Keyword(s):  
End Milling ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Generation Process ◽  
Burr Size ◽  
Milling Operation ◽  
Exit Burr

Burrs generated in micro-milling operation have a significant impact on the surface quality and operational performance of the finished microstructures. In order to gain a better recognition of burr generation process, 3-dimensional double-edged micro-flat end milling operation FEM models on Ti6Al4V have been established. Burrs occurred in simulation can be classified into three types: entrance burr, exit burr, top burr. Their formation processes and causes are well investigated and analyzed, moreover, a series of experiments are conducted to validate the burr morphologies which are received in simulation. At last, the effect of cutting parameters on top burr size is studied through orthogonal experiment on Ti6Al4V, it can be concluded that the axial depth of cut has the greatest effect on top burr size, and the effect of spindle speed on top burr size is the least.

Sign in / Sign up

Export Citation Format

Share Document