Metal Turning Mechanical Model of Machined Surface Roughness

2015 ◽  
Vol 1095 ◽  
pp. 770-772 ◽  
Author(s):  
Quan Li ◽  
Man Chen Xiong ◽  
Yin Yin Liu
Keyword(s):  
Surface Roughness ◽  
Mechanical Model ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Machined Surface ◽  
Undeformed Chip Thickness ◽  
Machined Surface Roughness

Consider the mechanism of the formation of surface roughness, this paper establish the mechanical model of undeformed chip thickness caused by the cutting edge,and the mechanical model of cutting residues caused by the tool feed movement . By means of Brammertz equation, combining the above two mechanical model,a more perfect surface roughness mechanical mode is established.

Machined Surface Roughness Geometry Model Development on Ultrasonic Vibration Assisted Micromilling with End Mill

2020 ◽  
Vol 846 ◽  
pp. 122-127
Author(s):  
Gandjar Kiswanto ◽  
Yolanda Rudy Johan ◽  
Poly ◽  
Tae Jo Ko
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Tool ◽  
Model Development ◽  
Cutting Edge ◽  
End Mill ◽  
Machined Surface ◽  
Workpiece Surface ◽  
Geometry Model ◽  
Machined Surface Roughness

Micro products or micro components are commonly used in today’s world. Research around micromanufacture technologies to produce a better product quality has been going on extensively. Ultrasonic vibration assisted micromilling (UVAM) is one of the technologies that can give a better machining qualities over the conventional ones. One of the benefits UVAM can give is reducing the machined surface roughness. The purpose of this paper is to give an idea how vibration assisted micromilling can give a better surface roughness quality. The theoritical surface roughness geometry model is made using MATLAB software. The cutting tool used in the simulation is end mill. There is a feature of the cutting tool called bottom cutting edge angle. This feature will be considered on this paper. The effects of the bottom cutting edge on workpiece machined surface can be looked visually from the simulation. Thus, the effects of cutting process using UVAM on the workpiece surface can be looked as well through the simulation.

Influence of Scratch Marks on Undeformed Chip Thickness in Ultra-Precision Cutting of Al-Mg Alloys

2017 ◽  
Vol 749 ◽  
pp. 27-32
Author(s):  
Keisuke Amaki ◽  
Yukio Maeda ◽  
Tomohiro Iida ◽  
Kazuya Kato ◽  
Hideaki Tanaka ◽  
...  
Keyword(s):  
High Efficiency ◽  
Surface Defects ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Mg Alloy ◽  
Glassy Material ◽  
Machined Surface ◽  
Undeformed Chip Thickness ◽  
Laser Printers ◽  
Ultra Precision

Recently, high efficiency and performance have become necessary attributes of information equipment such as laser printers. Thus, demand has increased for optical scanning parts that reduce optical aberration, scatter, and diffraction are required in laser printers. Polygon mirrors are manufactured by polishing a plating or glassy material to a mirror finish. In this study, we shortened the manufacturing process to improve the productivity and ultra-precision cutting technology of polygon mirrors made of aluminum. Thus, we had to reduce the geometric surface roughness achieved by mirror-cutting Al-Mg alloy and remove tear-out and scratch marks that occur during the cutting process. We investigated the cutting edge shape by using a straight diamond tool to decrease the surface defects produced during the ultra-precision cutting of Al-Mg alloy. We examined the mechanism for the occurrence of scratch marks and a method to reduce them. First, we measured the shape of the scratch marks and the cross-section with a scanning electron microscope. We found the tool collides with crystallization to produce small pieces, which then cause scratch marks. We developed a triple-facet tool with a double-facet at the end cutting edge to remove scratch marks and investigated the influence of surface defects. We clarified that using the triple-facet for a tool setting angle of 0° to 0.04° could achieve a good-quality machined surface without tear-out and scratch marks. In addition, the undeformed chip thickness was less than 80 nm

scholarly journals Study on Surface Roughness of Gcr15 Machined by Micro-Texture PCBN Tools

Machines ◽  
2018 ◽  
Vol 6 (3) ◽  
pp. 42 ◽  
Author(s):  
Chen Pan ◽  
Qinghua Li ◽  
Kaixing Hu ◽  
Yuxin Jiao ◽  
Yumei Song
Keyword(s):  
Surface Roughness ◽  
Cubic Boron Nitride ◽  
Bearing Steel ◽  
Cutting Edge ◽  
Machined Surface ◽  
Machined Surface Roughness ◽  
Influence Degree ◽  
Pcbn Tools ◽  
Cutting Speeds

This paper applies micro textures to the rake face of PCBN (Polycrystalline Cubic Boron Nitride) tools, including three types of micro textures that are microgroove textures vertical to the cutting edge, microgroove textures parallel to the cutting edge, and microhole textures. In this paper, the effects of different cutting speeds on the surface quality of hardened bearing steel GCr15 by dry turning with non-texture PCBN tools and micro-texture PCBN tools are studied, and the surface roughness values obtained by different micro textures were compared and analyzed. The results showed that, compared to that of non-texture tools, the influence degree of the micro-texture tools on the machined surface roughness was different. The microhole texture and vertical microgroove texture were able to effectively reduce the surface roughness of the workpiece, and microhole texture had the best effective influence on surface roughness, but the parallel microgroove texture increased surface roughness. The influence of cutting speeds on surface roughness was different due to different types of micro textures. The influence of micro textures on surface roughness has huge potential for tool applications.

Critical Feed/Tooth Value Providing Finest Machined Roughness by Peripheral Cutting with Micro Endmills

2016 ◽  
Vol 874 ◽  
pp. 232-237
Author(s):  
Yasunori Kobayashi ◽  
Haruhisa Sakamoto ◽  
Akihito Ishii ◽  
Masayori Itoh
Keyword(s):  
Surface Roughness ◽  
Chip Thickness ◽  
Machined Surface ◽  
Workpiece Surface ◽  
Machining Conditions ◽  
Machined Surface Roughness ◽  
Tool Diameter ◽  
Cutting Speeds ◽  
Machined Surfaces

This study concerns the rational determination of machining conditions for micro endmills that are less than 1.0mm in diameter. The characteristics of machined surface roughness are measured according to machining conditions, especially the feed per tooth Sz. The machined surfaces conditions are also observed with SEM. From the experiments, the following are made clear: (1) The feed per tooth Sz at the critical value Szc makes machined surface roughness the finest. (2) The conditions of Sz larger than Szc make cutting marks regular, that is, stable cutting can be done under those conditions, and then, the roughness improves according to decreasing Sz. (3) The conditions of Sz smaller than Szc cause irregular machined surfaces including pileups and diggings, that is, cutting becomes unstable conditions. The excessively thin chip-thickness prevents from stably engaging edge on workpiece surface. (4) Although the values of Szc are independent from the type of machine tools and cutting speeds, the values decrease according to decrease in tool diameter. (5) The value of Szc increases when tool has worn over its limit. Therefore, in order to determine machining conditions rationally, the changing behavior of Szc should be understood according to tool wear.

Effect of Cutting Edge Roundness on Work Hardened Surface Layer in Metal Cutting

2009 ◽  
Vol 407-408 ◽  
pp. 440-443
Author(s):  
Rikio Hikiji ◽  
Eiji Kondo ◽  
Minoru Arai
Keyword(s):  
Surface Layer ◽  
Surface Integrity ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Precision Machining ◽  
Machined Surface ◽  
Undeformed Chip Thickness ◽  
Ultra Precision ◽  
Machined Surface Integrity ◽  
Hardened Surface

In the ultra-precision machining, the smaller the undeformed chip thickness is, the more the machined surface integrity is affected by the cutting edge roundness of the cutting tool. In this research, the work hardened surface layer was dealt with as an evaluation of the machined surface integrity and the effect of the mechanical factors on work hardening was investigated experimentally in orthogonal cutting. In the case of a rounded cutting edge, unlike a sharp one, it makes the generation mechanism of the work hardened surface layer complicated. In this research, the mechanical dominant factors were investigated by comparing the effect of the rounded cutting edge on the work hardened surface layer, which counts for much in ultra precision machining involved in small undeformed chip thickness, with that of the sharp cutting edge.

scholarly journals Analytical Investigation of the Micro Groove Surface Topography by Micro-Milling

Micromachines ◽  
2019 ◽  
Vol 10 (9) ◽  
pp. 582 ◽  
Author(s):  
Jinfeng Zhang ◽  
Chao Feng ◽  
Hao Wang ◽  
Yadong Gong
Keyword(s):  
Surface Roughness ◽  
High Surface ◽  
Chip Thickness ◽  
Micro Milling ◽  
Theoretical Point ◽  
Machined Surface ◽  
Groove Surface ◽  
Surface Formation ◽  
Developed Surface ◽  
Machined Surface Roughness

Micro-milling is an emerging processing technology for machining micro- and high-precision three dimensional parts that require the use of various materials (with sizes ranging from tens of micrometers to a few millimeters) in the field of advanced manufacturing. Therefore, it can be applied to manufacture the micro parts, but new challenges are raised about parts with high surface quality. Herein, both surface formation and micro machined surface roughness models are studied, with the aim of solving complicated problems regarding the quality of surface finish when micro-milling metallic materials. From a theoretical point of view, the first model for surface formation processes considering the strain gradient plasticity theory was built in the area around the cutting edge, and the minimum uncut chip thickness equation was derived. The model accounts for the properties of the work material in tertiary and quaternary zones on the minimum chip thickness. A second model for micro machined surface roughness based on the relationship of kinematics between cutting process and cutter edge was also developed, which takes the influences of tool run out into account. Both proposed models were introduced to analyze the tendency of surface roughness for micro grooves. Both models were also used to justify experimental results. The results show that the developed surface roughness model could be useful in predicting both roughness parameters and trends as a function of cutting parameters.

Anticorrosion property enhancement of Al–Li alloy 2A97 by lowering machined surface roughness

2020 ◽  
Vol 71 (12) ◽  
pp. 1980-1988 ◽  
Author(s):  
Jintao Niu ◽  
Zhanqiang Liu ◽  
Guijie Wang ◽  
Weimin Huang ◽  
Ying Xu
Keyword(s):  
Surface Roughness ◽  
Anticorrosion Property ◽  
Machined Surface ◽  
Machined Surface Roughness

Experimental Investigation on Surface Roughness in Precision Cutting Ti6Al4V Alloy Using Diamond Tools

2014 ◽  
Vol 800-801 ◽  
pp. 576-579
Author(s):  
Lin Hua Hu ◽  
Ming Zhou ◽  
Yu Liang Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Cutting Parameters ◽  
Limited Range ◽  
Nose Radius ◽  
Machined Surface ◽  
Machined Surface Roughness ◽  
Titanium Alloy Ti6al4v ◽  
Pcd Tools

In this work, cutting experiments were carried out on titanium alloy Ti6Al4V by using polycrystalline diamond (PCD) tools to investigate the effects of the tool geometries and cutting parameters on machined surface roughness. Experimental results show machined surface roughness decreases with increases in the flank angle, tool nose radius and cutting speed within a limited range respectively, and begins to increase as the factors reaches to certain values respectively. And machined surface roughness decreases with increases in feed rate and cutting depth respectively.

COMPARISON OF PREPARATION METHODS IN TERMS OF TOOL LIFE AND SURFACE ROUGHNESS

2021 ◽  
Vol 2021 (4) ◽  
pp. 4836-4840
Author(s):  
ROBERT STRAKA ◽  
◽  
JOZEF PETERKA ◽  
TOMAS VOPAT ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Parameters ◽  
Turning Process ◽  
Machined Surface ◽  
Preparation Methods ◽  
Machined Surface Roughness ◽  
Cutting Inserts ◽  
Drag Finishing ◽  
Edge Preparation

The article compares two cutting edge preparation methods and their influence on the machined surface roughness of the difficult to cut nickel alloy Inconel 718 and the tool wear of cutting inserts made of cemented carbide. The manufacturing and preparation process of cutting inserts used in the experiment were made by Dormer Pramet. The preparation methods used in the experiment were drag finishing and brushing. Cutting parameters did not change during the whole turning process to maintain the same conditions in each step of the process and were determined based on tests for a semi-finishing operation of the turning process. To obtain durability of 25 to 30 minutes with controlled development of the tool wear the cutting parameters were determined with cooperation with the cutting inserts manufacturer.

Evaluation of DPI Change Impact on Laser Machined Surface Quality

2014 ◽  
Vol 474 ◽  
pp. 369-374
Author(s):  
Jana Knedlova ◽  
Libuše Sýkorová ◽  
Vladimír Pata ◽  
Martina Malachová
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Laser Micromachining ◽  
Technological Parameters ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Machined Surface Roughness ◽  
Change Impact

The article focuses on the field of PMMA laser micromachining at change of the technological parameters. The aim was to evaluate machined surface roughness at different setting of DPI definition (number of dots paths on square inch). Commercial CO2laser Mercury L-30 by firm LaserPro, USA was used for experimental machining. Ray of laser could be focused on mark diameter d=185 mm.

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