Monitoring and Prediction of Surface Roughness in Ball End Milling with Air Blow Application

2012 ◽  
Vol 538-541 ◽  
pp. 1332-1337 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Regression Analysis ◽  
Cutting Force ◽  
Multiple Regression Analysis ◽  
Prediction Accuracy ◽  
Prediction Interval ◽  
End Milling ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Roughness Model

This paper presents the additional work of the previous research in order to investigate the relations of the cutting conditions and the various air blow applications which affect the surface roughness. The suitable cutting condition is determined for the aluminum (Al6063) with the ball end milling by utilizing the response surface analysis referring to the minimum surface roughness. The cutting force is monitored during the cutting to analyze the surface roughness. The dynamometer is employed and installed on the table of 5-axis CNC maching center to measure the in-process cutting force. The models of surface roughness and cutting force are calculated by using the multiple regression analysis with the least squared method at 95% significant level. The experimentally obtained results showed that the surface roughness can be well explained by the in-process cutting force. The prediction accuracy and the prediction interval have been presented to verify the obtained surface roughness model at 95% confident level.

Intelligent Monitoring and Prediction of Surface Roughness in Ball-End Milling Process

2011 ◽  
Vol 121-126 ◽  
pp. 2059-2063 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Angsumalin Senjuntichai
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Prediction Accuracy ◽  
End Milling ◽  
Milling Process ◽  
Ball End Milling ◽  
Roughness Model ◽  
Force Ratio ◽  
Tool Diameter ◽  
End Milling Process

In order to realize the intelligent machines, the practical model is proposed to predict the in-process surface roughness during the ball-end milling process by utilizing the cutting force ratio. The ratio of cutting force is proposed to be generalized and non-scaled to estimate the surface roughness regardless of the cutting conditions. The proposed in-process surface roughness model is developed based on the experimentally obtained data by employing the exponential function with five factors of the spindle speed, the feed rate, the tool diameter, the depth of cut, and the cutting force ratio. The prediction accuracy and the prediction interval of the in-process surface roughness model at 95% confident level are calculated and proposed to predict the distribution of individually predicted points in which the in-process predicted surface roughness will fall. All those parameters have their own characteristics to the arithmetic surface roughness and the surface roughness. It is proved by the cutting tests that the proposed and developed in-process surface roughness model can be used to predict the in-process surface roughness by utilizing the cutting force ratio with the highly acceptable prediction accuracy.

Surface Roughness Prediction in Ball-End Milling Process for Aluminum by Using Air Blow Cutting

2011 ◽  
Vol 418-420 ◽  
pp. 1428-1434 ◽  
Author(s):  
Keerati Karunasawat ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Tool Diameter ◽  
End Milling Process

The objective of this research is to develop the surface roughness and cutting force models by using the air blow cutting of the aluminum in the ball-end milling process. The air blow cutting proposed in order to reduce the use of the cutting fluid. The surface roughness and cuttting force models are proposed in the exponential forms which consist of the cutting speed, the feed rate, the depth of cut, the tool diameter, and the air blow pressure. The coefficients of the surface roughness and cutting force models are calculated by utilizing the multiple regression with the least squared method at 95% significant level. The effects of cutting parameters on the cutting force are investigated and measured to analyze the relation between the surface roughness and the cutting conditions. The experimentally obtained results showed that the cutting force has the same trend with the surface roughness. The surface plots are constructed to determine the optimum cutting condition referring to the minimum surface roughness.

Investigation of Dry Cutting and Applications of Cutting Fluid in Ball-End Milling Process

2011 ◽  
Vol 291-294 ◽  
pp. 3013-3023 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Channarong Rungruang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Parameters ◽  
Milling Process ◽  
Cutting Fluid ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Ball End Milling ◽  
End Milling Process

In order to realize the environmental hazard, this paper presents the investigation of the machinability of ball-end milling process with the dry cutting, the wet cutting, and the mist cutting for aluminum. The relations of the surface roughness, the cutting force, and the cutting parameters are examined based on the experimental results by using the Response Surface Analysis with the Box-Behnken design. The in-process cutting force is monitored to analyze the relations of the surface roughness and the cutting parameters. The proper cutting condition can be determined easily referring to the minimum use of cutting fluid, and the minimum surface roughness and cutting force of the surface plot. The effectiveness of the obtained surface roughness and cutting force models have been proved by utilizing the analysis of variance at 95% confident level.

Applicability of Diamond-Coated Tools for Ball End Milling of Sintered Tungsten Carbide

2020 ◽  
Vol 14 (1) ◽  
pp. 18-25
Author(s):  
Haruhiko Suwa ◽  
Soushi Sakamoto ◽  
Masafumi Nagata ◽  
Kazuhiro Tezuka ◽  
Tetsuo Samukawa ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tungsten Carbide ◽  
End Milling ◽  
High Hardness ◽  
High Heat ◽  
Point Of View ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Ball End Milling ◽  
Sintered Tungsten

Sintered tungsten carbide which has high hardness and high heat resistance, has been widely used in molds and dies. Research on the development of a cutting technology for sintered tungsten carbide (sintered WC-Co alloy) has been pursued mainly with the use of a turning process. We focused on building an efficient milling method for sintered tungsten carbide by using diamond-coated ball end tools, and have investigated their basic properties under specific cutting conditions. This study extends our previous work by enhancing cutting distance in the milling of sintered tungsten carbide, especially that with a “fine” WC grain. The surface roughness of cut workpieces is evaluated from the point of view of the quality of surface roughness. A series of cutting experiments under different cutting conditions were carried out, and the possibility of deriving a suitable cutting condition for the ball end milling of sintered tungsten carbide is discussed.

In-Process Monitoring and Prediction of Surface Roughness in CNC Turning Process

2011 ◽  
Vol 199-200 ◽  
pp. 1958-1966 ◽  
Author(s):  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Prediction Accuracy ◽  
Cutting Speed ◽  
Least Square ◽  
Depth Of Cut ◽  
Turning Process ◽  
Roughness Model ◽  
Force Ratio ◽  
Cnc Turning Process

The objective of this research is to propose a practical model to predict the in-process surface roughness during the turning process by using the cutting force ratio. The proposed in-process surface roughness model is developed based on the experimentally obtain result by employing the exponential function with six factors of the cutting speed, the feed rate, the rank angle the tool nose radius, the depth of cut, and the cutting force ratio. The multiple regression analysis is utilized to calculate the regression coefficients with the use of the least square method. The prediction accuracy of the in-process surface roughness model has been verified to monitor the in-process predicted surface roughness at 95% confident level. All those parameters have their own characteristics to the arithmetic surface roughness and the surface roughness. It has been proved by the cutting tests that the proposed and developed in-process surface roughness model can be used to predict the in-process surface roughness by utilizing the cutting force ratio with the highly acceptable prediction accuracy.

Intelligent Monitoring and Estimation of Surface Roughness on CNC Turning

2010 ◽  
Vol 443 ◽  
pp. 376-381 ◽  
Author(s):  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Monitoring ◽  
Prediction Interval ◽  
Cutting Speed ◽  
Least Square ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Roughness Model ◽  
Force Ratio

In order to realize an intelligent machine tool, an in-process monitoring system is developed to estimate the in-process surface roughness. The objective of this research is to propose a method to estimate the surface roughness during the in-process cutting by utilizing the in-process monitoring of cutting forces. The proposed in-process surface roughness model is developed based on the experimentally obtained results by employing the exponential function with five factors of the cutting speed, the feed rate, the tool nose radius, the depth of cut, and the cutting force ratio. The multiple regression analysis is utilized to calculate the regression coefficients with the use of the least square method. The prediction interval of the in-process surface roughness model has been also presented to monitor and control the in-process estimated surface roughness at 95% confident level. It is proved by the cutting tests that the proposed and developed in-process surface roughness model can be effectively used to monitor and estimate the in-process surface roughness by utilizing the cutting force ratio with the highly acceptable prediction accuracy achieved.

Prediction of Surface Roughness on CNC Turning Based on Monitoring of Cutting Force and Cutting Temperature

2013 ◽  
Vol 690-693 ◽  
pp. 2540-2549 ◽  
Author(s):  
Somkiat Tangjitsitcharoen
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Experimental Results ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Cnc Turning ◽  
Roughness Model ◽  
Developed Surface ◽  
Coated Carbide

This paper presents the surface roughness model which is proposed and developed to predict the surface roughness in the CNC turning of the carbon steel with the coated carbide tool under various cutting conditions by using the response surface analysis with the Box-Behnken design based on the experimental results. The in-process monitoring of the cutting force and the cutting temperature is utilized to analyze the relation between the surface roughness and the cutting condition. The tool dynamometer and the infrared pyrometer are employed and installed on the turret of CNC turning machine to measure the in-process cutting force and cutting temperature. The models of cutting force ratio and cutting temperature are also developed based on the experimental data. The optimum cutting condition is determined referring to the minimum surface roughness of the surface plot, which is obtained from the developed surface roughness model. The experimental results show that the higher cutting speed gives the better surface roughness due to the higher cutting temperature, however the tool life becomes shorter. The feed rate is the most significant factor which affects the surface roughness, while a small depth of cut helps to improve the surface roughness. The effectiveness of the surface roughness prediction model has been proved by utilizing an analysis of variance (ANOVA) at 95% confident level. Hence, the surface roughness can be predicted and obtained easily referring to the developed surface roughness model.

scholarly journals Research on Homogenization and Surface Integrity of Ti-6Al-4V Alloy by Longitudinal-Torsional Coupled Ultrasonic Vibration Ball-End Milling

2018 ◽  
Author(s):  
Wanfei Ren ◽  
Jinkai Xu ◽  
Jieqiong Lin ◽  
Zhanjiang Yu ◽  
Peng Yu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Residual Stresses ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
High Frequency ◽  
End Milling ◽  
Cutting Speed ◽  
Ball End Milling ◽  
Average Value ◽  
Cutting Experiments

This paper aims to study the surface homogenization and integrity of Ti-6Al-4V alloy by longitudinal-torsional coupled ultrasonic vibration assisted ball-end milling. A method of continuous processing between the flat surface and freeform surface connection is proposed by using ultrasonic vibration assisted ball-end precision milling, during this process, it is not necessary to exchange the cutting tool. The way has been explored for changing the homogenization of surface on Ti-6Al-4V by ultrasonic vibration-assisted milling (UVAM). Cutting experiments employing three parameters, cutting speed, feed rate and depth of cut and two types of machining forms using ball-end milling with UVAM and conventional milling (CM) respectively. The high frequency cutting force, finished surface roughness, topography and residual stresses on the surface and tool wear have been measured by advanced instruments. Particularly, adopting the high frequency cutting force measurement system, it is concluded cutting force in ball-end milling decreased significantly using UVAM as against CM. Moreover, the surface roughness by UVAM with ball-end milling is much better than the CM at a high cutting speed. However, an opposite trend is observed at a low cutting speed. Especially, there is a steep decrease from Ra 0.828 μm average value at 4000 rpm to Ra 0.129 μm average value at 5000 rpm. At the same time, the homogenization of surface roughness and residual stresses decrease significantly in UVAM as compared to which in CM when taking the transversal-longitudinal ratio into consideration. Cutting experiments and measuring results are demonstrated the validity and feasibility of UVAM with ball-end milling, and this method enjoys significant advantages compared to CM process.

A wavelet approach to predict surface roughness in ball-end milling

2015 ◽  
Vol 231 (14) ◽  
pp. 2468-2478 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Prae Thesniyom ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Wavelet Transform ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Detection System ◽  
Milling Process ◽  
Cutting Conditions ◽  
Ball End Milling ◽  
Dynamic Cutting Force

This research proposed an advance in the prediction of the in-process surface roughness during the ball-end milling process by utilizing the wavelet transform to monitor and decompose the dynamic cutting forces. The chatter detection system has been adopted from the previous research of the author to avoid the chatter first, and hence, the dynamic cutting force ratio is introduced to predict the in-process surface roughness during the normal cutting by taking the ratio of the decomposed dynamic cutting force in X axis to that in Z axis. The Daubechies wavelet transform is employed in this research to analyze the in-process surface roughness. The experimentally obtained results showed that the surface roughness frequency occurred at the same level of the decomposed dynamic cutting forces although the cutting conditions are changed. It is understood that the in-process surface roughness can be predicted effectively under various cutting conditions referring to the proposed monitoring system.

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