Ball-End Milling of Cr12MoV Die Steel Using Ceramic Tool and Cements Carbide Tool

2012 ◽  
Vol 565 ◽  
pp. 466-471
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Zi Ye Liu ◽  
Xin Qiang Zhuang ◽  
Jun Wang
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Cutting Tools ◽  
Cutting Conditions ◽  
Cemented Carbide ◽  
Cutting Condition ◽  
Die Steel ◽  
Ball End Milling ◽  
Carbide Insert ◽  
Ceramic Insert

Ball-end milling of Cr12MoV die steel was studied using ceramic and cemented carbide inserts under different cutting conditions. The cutting forces, wear patterns and chip patterns generated using the different cutting tools at the different cutting conditions were investigated using a three component piezoelectric dynamometer and VHX-600E large depth-of-view 3-D scanner. The relationships among the cutting forces, wear patterns and chip patterns were discussed. The results indicated that the cutting forces caused by the ceramic insert were slightly lower than those caused by the cemented carbide insert under the same cutting conditions. For ceramic inserts, effects of cutting conditions on the rake face wear were different from those on the flank wear. The higher wear for the ceramic insert was caused at the lower cutting conditions but the higher wear for the cemented carbide insert was encountered at the higher cutting conditions. The squeezed chip was involved with the higher cutting forces. The sharper cutting edge of the cemented carbide insert was responsible for chip patterns caused by the No. I cutting condition. The effects of cutting conditions on wear patterns were more evident than that on chip patterns.

Tool Wear in Ball-End Milling of Cr12MoV Die Steel Using an Indexable Cutter with the Asymmetric Inserts

2012 ◽  
Vol 500 ◽  
pp. 111-116
Author(s):  
Bin Zou ◽  
Chuan Zhen Huang ◽  
Zi Ye Liu ◽  
Xin Qiang Zhuang ◽  
Jun Wang
Keyword(s):  
Tool Wear ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Die Steel ◽  
Ball End Milling ◽  
Diffusion Wear ◽  
Flank Face ◽  
And Diffusion

Tool wear was investigated at the different cutting conditions in rough ball-end milling of Cr12MoV die steel using an indexable cutter with asymmetric inserts. The wear patterns on rake face and flank face of major insert and minor insert, and chip patterns were observed by VHX-600E large depth-of-view 3-D scanner. The relationships of tool wear and cutting conditions, and their mechanisms were discussed. The tool life was determined by the flank wear at No. 1 cutting condition. At Nos. 2-8 cutting conditions, the life of major inset and minor insert were determined by the wear of their rake faces and flank faces respectively. At No. 8 cutting condition, the tool wear was dominated by boundary wear, adhesion and diffusion wear, and the slight chipping. Both type and color of chips identified the cutting stability at the different cutting conditions.

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.

Prediction of Ball End Milling Forces

1996 ◽  
Vol 118 (1) ◽  
pp. 95-103 ◽  
Author(s):  
G. Yu¨cesan ◽  
Y. Altıntas¸
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Cutting Conditions ◽  
Analytic Representation ◽  
Rake Face ◽  
Uncut Chip Thickness ◽  
Ball End Milling ◽  
Helical Flute ◽  
Milling Forces

Mechanics of milling with ball ended helical cutters are modeled. The model is based on the analytic representation of ball shaped helical flute geometry, and its rake and clearance surfaces. It is assumed that friction and pressure loads on the rake face are proportional to the uncut chip thickness area. The load on the flank contact face is concentrated on the in cut portion of the cutting edge. The pressure and friction coefficients are identified from a set of slot ball end milling tests at different feeds and axial depth of cuts, and are used to predict the cutting forces for various cutting conditions. The experimentally verified model accurately predicts the cutting forces in three Cartesian directions.

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.

Surface Roughness Identification in End Milling Using Vibration Signals and Fuzzy Clustering

2016 ◽  
Author(s):  
Issam Abu-Mahfouz ◽  
Amit Banerjee ◽  
A. H. M. Esfakur Rahman
Keyword(s):  
Surface Roughness ◽  
Fuzzy Clustering ◽  
Wavelet Transforms ◽  
Fourier Transforms ◽  
End Milling ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Machined Surface ◽  
Vibration Signals

The study presented involves the identification of surface roughness in Aluminum work pieces in an end milling process using fuzzy clustering of vibration signals. Vibration signals are experimentally acquired using an accelerometer for varying cutting conditions such as spindle speed, feed rate and depth of cut. Features are then extracted by processing the acquired signals in both the time and frequency domain. Techniques based on statistical parameters, Fast Fourier Transforms (FFT) and the Continuous Wavelet Transforms (CWT) are utilized for feature extraction. The surface roughness of the machined surface is also measured. In this study, fuzzy clustering is used to partition the feature sets, followed by a correlation with the experimentally obtained surface roughness measurements. The fuzzifier and the number of clusters are varied and it is found that the partitions produced by fuzzy clustering in the vibration signal feature space are related to the partitions based on cutting conditions with surface roughness as the output parameter. The results based on limited simulations are encouraging and work is underway to develop a larger framework for online cutting condition monitoring system for end milling.

Analysis of Cutting Forces and Machining Error in Ball End Milling of Cylindrical Surfaces

2011 ◽  
Vol 328-330 ◽  
pp. 560-564
Author(s):  
Ba Sheng Ouyang ◽  
Guo Xiang Lin ◽  
Yong Hui Tang
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Cutting Conditions ◽  
Machining Error ◽  
Machined Surface ◽  
Convex Surfaces ◽  
Machining Errors ◽  
End Mills ◽  
Tool Deflections ◽  
Cutting Modes

Cutting forces and machining error in contouring of concave and convex surfaces using helical ball end mills are theoretically investigated. The cutting forces are evaluated based on the theory of oblique cutting. The machining errors resulting from the tool deflections due to these forces are evaluated at various points of the machined surface. The influence of various cutting conditions and cutting modes on machining error is investigated and discussed.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

scholarly journals Experimental Verification of Chatter-Free Ball End Milling Strategy

2013 ◽  
Vol 7 (1) ◽  
pp. 45-51 ◽  
Author(s):  
Lin Lu ◽  
◽  
Masahiko Sato ◽  
Hisataka Tanaka ◽  
Keyword(s):  
Cutting Tool ◽  
End Milling ◽  
Cutting Parameters ◽  
Cutting Condition ◽  
Chatter Stability ◽  
Chatter Vibration ◽  
Ball End Milling ◽  
Machining Center ◽  
Avoidance Control ◽  
Avoidance Strategy

Chatter vibration frequently occurs in ball end milling. If the characteristics of the cutting tool system and cutting process are known, chatter stability in ball end milling can be evaluated. Hence, in this paper, a chatter-avoidance strategy based on a regenerative chatter theory is proposed to prevent the occurrence of chatter. This consists of a simulation of chatter stability and cutting condition control. When the characteristics of a vibration system change, this chatter-avoidance strategy cannot cope with it. Therefore, another chatter-avoidance control algorism that changes cutting parameters on a machining center is proposed. This can adapt to the change in the characteristics of the vibration systemduring cutting. The effectiveness of the two chatter-avoidance methods proposed is examined through experiments.

Analytical Convolution Model of Cutting Forces in 3-D Ball End Milling

2001 ◽  
Author(s):  
Richard Y. Chiou ◽  
Bing Zhao
Keyword(s):  
Cutting Force ◽  
Frequency Domain ◽  
Cutting Forces ◽  
End Milling ◽  
Force Model ◽  
Three Dimensional Model ◽  
Calculation Algorithm ◽  
Ball End Milling ◽  
Convolution Model ◽  
Force Calculation

Abstract This paper presents an analytical convolution model of dynamic cutting forces in ball end milling of 3-D plane surfaces. The model takes into account the instantaneous slope on a sculptured surface to establish the chip geometry in cutting force calculation algorithm. A three-dimensional model of cutting forces in ball end milling is presented in terms of material properties, cutting parameters, machining configuration, and tool/work geometry. Based on the relationship of the local cutting force, chip load and engaged boundary, the total cutting force model is established via the angle domain convolution integration of the local forces in the feed, cross feed, axial direction, and inclination angle. The convolution integral leads to a periodic function of cutting forces in the angle domain and an explicit expression of the dynamic cutting force components in the frequency domain. Following the theoretical analysis, experimental study is discussed to illustrate the implementation procedure for force identification, and frequency domain data are presented to verify the analytical results.

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