Surface Finish Study of Hard Milling 45 Steel with PCBN Tool

2012 ◽  
Vol 468-471 ◽  
pp. 1467-1470 ◽  
Author(s):  
Rui Jie Wang ◽  
Yong Liang Zhang ◽  
Hong Bin Liu ◽  
Mao Hua Du
Keyword(s):  
Surface Finish ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
Hard Milling ◽  
Pcbn Tool ◽  
High Speed Milling ◽  
Feeding Speed ◽  
Tool Cutting

Experimental study on surface finish of high speed mill of hardened 45 steel was carried out with PCBN tool. Cutting parameters studied include different cutting depth, cutting speed and feeding speed. Surface finish after cutting were measured and compared with that of grinding. Experimental results showed that for high speed milling of hardened 45 steel, the surface finish can be very fine, different cutting parameters all have explicit effect on surface finish.

Effects of Cutting Parameters on Residual Stresses in High-Speed Milling of Ti-17

2013 ◽  
Vol 834-836 ◽  
pp. 861-865 ◽  
Author(s):  
Yong Shou Liang ◽  
Jun Xue Ren ◽  
Yuan Feng Luo ◽  
Ding Hua Zhang
Keyword(s):  
Experimental Study ◽  
Residual Stresses ◽  
High Speed ◽  
Experimental Parameter ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Single Factor ◽  
Cutting Depth ◽  
High Speed Milling ◽  
Parameter Ranges

An experimental study was conducted to determine cutting parameters of high-speed milling of Ti-17 according to their effects on residual stresses. First, three groups of single factor experiments were carried out to reveal the effects of cutting parameters on residual stresses. Then sensitivity models were established to evaluate the influence degrees of cutting parameters on residual stresses. After that, three criteria were proposed to determine cutting parameters from experimental parameter ranges. In the experiments, the cutting parameter ranges are recommended as [371.8, 406.8] m/min, [0.363, 0.412] mm and [0, 0.018] mm/z for cutting speed, cutting depth and feed per tooth, respectively.

Measurement and Analysis of Cutting Force and Optimization of Cutting Parameters by High Speed Milling

2011 ◽  
Vol 141 ◽  
pp. 344-349
Author(s):  
Hu Zeng Li ◽  
Yi Wang ◽  
Nai Xiong Zhu ◽  
Rao Bo Hu ◽  
Chong Zhang ◽  
...  
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
High Speed Milling ◽  
High Cutting Speed ◽  
High Feed ◽  
Optimization Of Cutting Parameters

The measurement method and apparatus of cutting force by high speed milling is introduced. The high speed milling force of wrought aluminum alloy is measured and analyzed through separately examining the influences of various factors, such as cutting speed, cutting depth, milling width, feed per cutting tooth, down or up milling, cooling and lubricating. The results match with outcomes from other’s tests and the theory of metal cutting, and are close to the calculated force values, so that the test can be regarded as positive. It is pointed out that high cutting speed, little cutting depth, properly great working engagement and feed per tooth, high feed rate, down milling and efficient cooling and lubricating should be used to reduce cutting force and deformation, to improve milling accuracy and efficiency, which can be helpful to the spread applications of High Speed Machining.

Experimental Study on Cutting Force and Surface Roughness for 7050-T7451 Aluminum Alloy of High Speed Milling

2013 ◽  
Vol 395-396 ◽  
pp. 1026-1030 ◽  
Author(s):  
Zhao Lin Zhong ◽  
Xing Ai ◽  
Zhan Qiang Liu
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Experimental Results ◽  
Cutting Depth ◽  
High Speed Milling ◽  
Thermodynamic Relationship

This paper presents the experimental results of cutting force and surface roughness of 7050-T7451 aluminum alloy under the cutting speed of 3000~5000m/min. The cutting forces and surface roughness with different cutting parameters were analyzed. Experimental results suggested that increasing cutting speed would engender thermal softening, which would in return affect the cutting force and surface roughness in high speed milling. The cutting force and surface roughness were affected by cutting depth and feed rate obviously. Surface roughness was also affected by cutting width which changed the cutting force slightly. According to the results, proper parameters could be selected and thermodynamic relationship needed to be discussed for further research.

The Application of FEA in High-Speed Cutting

2011 ◽  
Vol 287-290 ◽  
pp. 104-107
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
High Speed ◽  
Feeding Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Material Model ◽  
Friction Model ◽  
Cutting Depth ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools and cutting parameters are determinted by simulating the influences of cutting speed, cutting depth and feeding rate on the cutting parameters using FEA.

Force and Temperature in Dry Cutting of Hardened W18Cr4V with PCBN

2010 ◽  
Vol 431-432 ◽  
pp. 559-563
Author(s):  
Hai Rong Wu ◽  
Guo Qin Huang ◽  
Xi Peng Xu
Keyword(s):  
Experimental Study ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
Dry Cutting ◽  
Feeding Speed ◽  
Strain Gauge Dynamometer ◽  
Three Components

An experimental study was carried out to investigate the effects of cutting parameters on cutting force and temperature in cutting of hardened W18Cr4V with PCBN cutter. Three components of cutting force were recorded by a strain-gauge dynamometer and the cutting temperature was measured by a nature thermocouple of tool-workpiece. The cutting parameters were arranged by orthogonal method. It is shown that the cutting temperature increased with each of the three cutting parameters and the main effecting factor is feeding speed. The three components of cutting force increased greatly with an increase in feeding speed and cutting depth. But the forces decreased a little as cutting speed increased. The main and axial cutting forces depend mainly on cutting depth whereas the radius force is mainly influenced by feeding speed.

The Research on Milling Force in High-Speed Milling Nickel-Based Superalloy of Inconel 718

2013 ◽  
Vol 395-396 ◽  
pp. 1031-1034
Author(s):  
Can Zhao ◽  
Yu Bo Liu
Keyword(s):  
Cutting Force ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Depth ◽  
Milling Force ◽  
High Speed Milling ◽  
Nickel Based Superalloy ◽  
Cutting Speeds

This paper makes an experiment in high-speed milling of Inconel 718. Cutting tests were performed using round and ceramic tools, at feeds from 0.06 to 0.14 mm/tooth, Axial Depth of Cut from0.5 to 1.5mm,and cutting speeds ranging from 500 to 1037 m/min. The behaviour of the cutting forces during machining was then measure. The results show that cutting force increases first and then decreases with the increase of feed per tooth, the tool chipping and groove wear were found with the increase of axial cutting depth, and cutting force is increased; the increase in cutting force with the cutting speed increases, when the cutting speed reaches a critical speed, the cutting force as the cutting speed increases began to decline.

Prediction of Surface Roughness in High Speed Machining of Inconel 718

2011 ◽  
Vol 264-265 ◽  
pp. 1193-1198
Author(s):  
Mokhtar Suhaily ◽  
A.K.M. Nurul Amin ◽  
Anayet Ullah Patwari
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Depth Of Cut ◽  
High Speed Machining

Surface finish and dimensional accuracy is one of the most important requirements in machining process. Inconel 718 has been widely used in the aerospace industries. High speed machining (HSM) is capable of producing parts that require little or no grinding/lapping operations within the required machining tolerances. In this study small diameter tools are used to achieve high rpm to facilitate the application of low values of feed and depths of cut to investigate better surface finish in high speed machining of Inconel 718. This paper describes mathematically the effect of cutting parameters on Surface roughness in high speed end milling of Inconel 718. The mathematical model for the surface roughness has been developed in terms of cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). Central composite design was employed in developing the surface roughness models in relation to primary cutting parameters. Machining were performed using CNC Vertical Machining Center (VMC) with a HES510 high speed machining attachment in which using a 4mm solid carbide fluted flat end mill tool. Wyko NT1100 optical profiler was used to measure the definite machined surface for obtaining the surface roughness data. The predicted results are in good agreement with the experimental one and hence the model can be efficiently used to predict the surface roughness value with in the specified cutting conditions limit.

scholarly journals Optimizing the High-Performance Milling of Thin Aluminum Alloy Plates Using the Taguchi Method

Metals ◽  
2021 ◽  
Vol 11 (10) ◽  
pp. 1526
Author(s):  
Cheng-Hsien Kuo ◽  
Zi-Yi Lin
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Parameters ◽  
Linear Velocity ◽  
Cutting Depth ◽  
Degree Of Deformation ◽  
High Speed Milling ◽  
The Impact

Most aerospace parts are thin walled and made of aluminum or titanium alloy that is machined to the required shape and dimensions. Deformation is a common issue. Although the reduced cutting forces used in high-speed milling generate low residual stress, the problem of deformation cannot be completely resolved. In this work, we emphasized that choosing the correct cutting parameters and machining techniques could increase the cutting performance and surface quality and reduce the deformation of thin plates. In this study, a part made of a thin 6061 aluminum alloy plate was machined by high-speed milling (HSM), and a Taguchi L16 orthogonal array was used to optimize the following parameters: linear velocity, feed per tooth, cutting depth, cutting width, and toolpath. The impact of cutting parameters on the degree of deformation, surface roughness, as well as the cutting force on the thin plate were all investigated. The results showed that the experimental parameters for the optimal degree of deformation were A1 (linear velocity 450 mm/min), B1 (feed per tooth 0.06 mm/tooth), C1 (cutting depth 0.3 mm), D4 (cutting width 70%), and E4 (rough zigzag). Feed per tooth was the most significant control factor, with a contribution as high as 63.5%. It should also be mentioned that, according to the factor response of deformation, there was a lower value of feed per tooth and less deformation. Furthermore, the feed per tooth and the cutting depth decreased and the surface roughness increased. The cutting force rose or fell with an increase or decrease of cutting depth.

Analysis of Vibration Amplitude in High-Speed Cutting for Hardened Steel

2015 ◽  
Vol 667 ◽  
pp. 9-14
Author(s):  
Guang Jun Chen ◽  
Liang Wang ◽  
Bai Ting He ◽  
Ling Guo Kong ◽  
Xiao Qin Zhou
Keyword(s):  
Feed Rate ◽  
Vibration Amplitude ◽  
High Speed ◽  
Great Influence ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Hardened Steel ◽  
Cutting Depth ◽  
Corner Radius ◽  
Cutting Vibration

The cutting vibration has a great influence on the processing quality of Hardened steel. The research conducted in this paper is about how the cutting parameters influence the cutting vibration amplitude when the hardened steel is cut. The experiments were performed on CNC lathe CAK4085 with PCBN tool, where the cutting speed, feed rate, cutting depth and corner radius had been orthogonally combined. The cutting materials were hardened steel Cr12MoV and GCr15 whose hardness is HRC50-52 and HRC62-64. The cutting vibration amplitude under different group parameters was collected by electric eddy current sensors. An analysis about the influence rule of cutting parameters on cutting vibration amplitude had been made. With the increase of cutting speed, vibration amplitude will increase first, and then decrease. With the appropriate increase of feed rate, vibration amplitude will be reduced. With the increase of cutting depth and corner radius, vibration amplitude will both increase. This research can provide reference for improving cutting quality.

Study on Cutting Forces of Mg-6Nd-4Gd-3Y Magnesium Alloy in High-Speed Milling

2011 ◽  
Vol 338 ◽  
pp. 709-713
Author(s):  
Zhen Hua Wang ◽  
Jun Tang Yuan
Keyword(s):  
Magnesium Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Polynomial Regression ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Partial Least Square ◽  
Depth Of Cut ◽  
High Speed Milling

In this paper, 24full factorial design and homogeneous design were applied to the high-speed milling experiments for Mg-6Nd-4Gd-3Y magnesium alloy. According to the experimental results of cutting force, the effect of cutting parameters (cutting speed, feed per tooth, depth of cut, and width of cut) on cutting force was discussed, and the nonlinear polynomial regression models of cutting forces based on the cutting parameters were presented by the partial least-square regression.

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