Analysis of Surface Roughness for High Speed Milling of a Magnesium Alloy Part

2013 ◽  
Vol 837 ◽  
pp. 33-38 ◽  
Author(s):  
Bogdan Chirita ◽  
Nicolae Catalin Tampu
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Surface Quality ◽  
Product Life Cycle ◽  
High Speed ◽  
Fatigue Behavior ◽  
Cutting Parameters ◽  
Good Surface ◽  
Cooling Conditions ◽  
Higher Temperature

Surface roughness represents an important characteristic in the appreciation of a part quality. A good surface quality can enhance corrosion resistance and fatigue behavior throughout product life cycle. Magnesium alloys have gained in the recent years a larger use due to an excellent ratio between mechanical strength and weight. Cooling conditions are particularly important when machining magnesium. The chips are flammable and highly reactive with water based fluids. Higher temperature favors also the formation [email protected] built-up edge and worsens surface quality. The present paper analyses the influence of cooling conditions and cutting parameters on surface roughness of the parts made of magnesium alloy. Using design of experiments technique, a series of experiments were organized and based on that a connection between surface quality and cutting conditions was established.

SURFACE ROUGHNESS OF MAGNESIUM ALLOY AZ91D IN HIGH SPEED MILLING

2016 ◽  
Vol 78 (6-9) ◽  
Author(s):  
Mohd Shahfizal Ruslan ◽  
Kamal Othman ◽  
Jaharah A.Ghani ◽  
Mohd Shahir Kassim ◽  
Che Hassan Che Haron
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Parameters ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Polishing Process ◽  
High Speed Cutting ◽  
Radial Depth

Magnesium alloy is a material with a high strength to weight ratio and is suitable for various applications such as in automotive, aerospace, electronics, industrial, biomedical and sports. Most end products require a mirror-like finish, therefore, this paper will present how a mirror-like finishing can be achieved using a high speed face milling that is equivalent to the manual polishing process. The high speed cutting regime for magnesium alloy was studied at the range of 900-1400 m/min, and the feed rate for finishing at 0.03-0.09 mm/tooth. The surface roughness found for this range of cutting parameters were between 0.061-0.133 µm, which is less than the 0.5µm that can be obtained by manual polishing. Furthermore, from the S/N ratio plots, the optimum cutting condition for the surface roughness can be achieved at a cutting speed of 1100 m/min, feed rate 0.03 mm/tooth, axial depth of cut of 0.20 mm and radial depth of cut of 10 mm. From the experimental result the lowest surface roughness of 0.061µm was obtained at 900 m/min with the same conditions for other cutting parameters. This study revealed that by milling AZ91D at a high speed cutting, it is possible to eliminate the polishing process to achieve a mirror-like finishing.

Surface Quality Prediction in Case of Steep Free Form Surface Milling

2016 ◽  
Vol 686 ◽  
pp. 119-124 ◽  
Author(s):  
Balázs Mikó
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Tool Path ◽  
Complex Geometry ◽  
Cutting Parameters ◽  
Free Form ◽  
Milling Cutter ◽  
Good Surface ◽  
2.5D Milling ◽  
Free Form Surfaces

The machining of free form surfaces is a current and important issue in die and mould industry. Beside the complex geometry, an accurate and productive machining and good surface quality are needed. The finishing milling carried out by a ball-end or toroid milling cutter defines the surface quality, which is characterized by the surface roughness and the tool path trace. The surface quality is defined by the properties of the milling cutter, the type of surface and its position, as well as the cutting parameters. This article focuses on the z-level milling of steep surfaces by 2.5D milling strategy. The importance of the different elements of the tool path is presented, the effect of cutting parameters is investigated, and a formula to predict the surface roughness is suggested.

scholarly journals Surface Quality Assessment after Milling AZ91D Magnesium Alloy Using PCD Tool

Materials ◽  
2020 ◽  
Vol 13 (3) ◽  
pp. 617 ◽  
Author(s):  
Ireneusz Zagórski ◽  
Jarosław Korpysa
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Roughness Parameters ◽  
Operational Parameters

Surface roughness is among the key indicators describing the quality of machined surfaces. Although it is an aggregate of several factors, the condition of the surface is largely determined by the type of tool and the operational parameters of machining. This study sought to examine the effect that particular machining parameters have on the quality of the surface. The investigated operation was the high-speed dry milling of a magnesium alloy with a polycrystalline diamond (PCD) cutting tool dedicated for light metal applications. Magnesium alloys have low density, and thus are commonly used in the aerospace or automotive industries. The state of the Mg surfaces was assessed using the 2D surface roughness parameters, measured on the lateral and the end face of the specimens, and the end-face 3D area roughness parameters. The description of the surfaces was complemented with the surface topography maps and the Abbott–Firestone curves of the specimens. Most 2D roughness parameters were to a limited extent affected by the changes in the cutting speed and the axial depth of cut, therefore, the results from the measurements were subjected to statistical analysis. From the data comparison, it emerged that PCD-tipped tools are resilient to changes in the cutting parameters and produce a high-quality surface finish.

Research and Application of Wire Cutting Mold Surface Roughness

2012 ◽  
Vol 217-219 ◽  
pp. 1577-1580
Author(s):  
Xiao Long Shen ◽  
Lai Xi Zhang ◽  
Nan Lin Yu
Keyword(s):  
Surface Roughness ◽  
Theoretical Analysis ◽  
Surface Quality ◽  
High Speed ◽  
Mold Surface ◽  
Surface Processing ◽  
Surface Machining ◽  
Good Surface ◽  
Wire Cutting ◽  
Discharge Gap

The article aimed at mold parts surface machining, has been studied high speed wire cutting technology. Explored the process evaluation factors which impact wire cutting mold based on the theoretical analysis of the wire cutting discharge gap and the surface processing finish of the mold parts. By studying the two main elements which affect the mold parts surface roughness processing, measures of improve and enhance wire cutting mold surface roughness are proposed. Only the comprehensive account of various factors can obtain mould parts processing good surface quality. The research methods and conclusion have provided reference on solving the problem of mold parts surface roughness by WEDM.

Influence of Cutting Parameters on the Surface Quality of Round Parts Made from AZ61 Magnesium Alloy and Machined by Turning

2013 ◽  
Vol 837 ◽  
pp. 128-134 ◽  
Author(s):  
Gheorghe Mustea ◽  
Gheorghe Brabie
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Magnesium Alloy ◽  
Surface Quality ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Az61 Magnesium Alloy ◽  
Machined Surfaces

The use of magnesium alloys in construction of different components of the mechanical systems (such: cars, aerospace vehicles, medical equipment etc.) is very efficient not only because it leads to reduction of the systems weight but also because it leads to reduction or elimination of the environment polluting and to reduction of the energy consumption. Generally, the main factors that influence the quality of the machined surfaces are as follows: cutting parameters, material properties, geometry of the tools, cooling liquids and lubricants, physical and mechanical properties of the subsurface layers etc. Among the above mentioned factors, cutting parameters are the factors that strongly influence the quality of the machined surfaces. The present paper analysis the results of the experimental investigation performed to determine the influence of cutting parameters (cutting speed, feed rate and cutting depth) on the surface quality machined by turning the AZ61 magnesium alloy. The main characteristics of the machined surface quality analyzed in experimental investigation were the surface roughness and hardness. The main conclusions resulted from the results analysis were as follows: the decrease of the feed rate led to surface roughness decrease and hardness increase; the increase of the cutting speed also led to an improved surface quality.

Study on Surface Roughness in High-Speed Milling for ALMn1Cu

2012 ◽  
Vol 157-158 ◽  
pp. 636-640 ◽  
Author(s):  
Zhen Hua Wang ◽  
Jun Tang Yuan ◽  
Jun Huang
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Analysis Of Variance ◽  
High Speed ◽  
Cutting Parameters ◽  
Factorial Experiments ◽  
Machined Surface ◽  
High Speed Milling ◽  
Machined Surface Quality ◽  
Cutting Experiments

Anti-rust aluminum is widely used in aviation, aerospace, communications, as well as weapons with non-corrosion, light, and other fine characteristic. In this study, in order to improve the machined surface quality and reduce the surface roughness and find the influence of the cutting parameters on the surface roughness, a series of cutting experiments for AlMn1Cu are conducted to obtain surface roughness values in high-speed milling. According to the analysis of variance (ANOVA) of factorial experiments, the cutting parameters significantly influencing on the surface roughness were presented.

Deep-Hole Single-Edge Technology Test of Rigid Reamer

2011 ◽  
Vol 120 ◽  
pp. 296-303
Author(s):  
Xing Quan Shen ◽  
Yao Ming Li ◽  
Hai Jiao Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
High Speed ◽  
Cutting Parameters ◽  
Deep Hole ◽  
Single Edge ◽  
High Speed Cutting ◽  
Extrusion Processing ◽  
The Impact

Single-edge rigid reaming process has high-speed cutting rigid hinge processing, auto-oriented, low surface roughness of a series of advantages. In this paper, by using of the elastic and plastic theory, we studied the effect of the force acting on the guide block extrusion on the hole wall, proposed the two different cutting states of single-edge rigid reaming processing, and analyzed the conditions of the reaming processing in the extrusion state. By the analysis of experiments, we obtained that in order to achieve the good hole processing surface quality we must make the reaming processing in the extrusion processing state, and we determined the impact of the cutting parameters on the cutting force and surface roughness.

High Speed Milling of Turbine Blades

1994 ◽  
Author(s):  
Herbert Schulz ◽  
Stefan Hock
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Machine Tools ◽  
High Speed ◽  
Turbine Blades ◽  
Cutting Parameters ◽  
Surface Finishing ◽  
Tool Geometry ◽  
High Speed Milling ◽  
High Speed Cutting

The efficiency of steam- and gasturbines is mainly influenced by the geometry and the surface roughness of the turbine blades. Therefore the profile contour of the blades must be machined as accurate as possible. High speed cutting (hsc) offers a lot of advantages for surface finishing of turbine blades. The paper describes the influence of different cutting parameters as well as the importance of tool geometry for the surface quality achievable by high speed milling. Specific requirements for machine tools for high speed milling will be discussed.

Theoretical Surface Roughness Model in High Speed Face Milling

2014 ◽  
Vol 989-994 ◽  
pp. 3331-3334
Author(s):  
Tao Zhang ◽  
Guo He Li ◽  
L. Han
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
High Speed ◽  
Cutting Parameters ◽  
Angular Speed ◽  
Face Milling ◽  
Advanced Manufacturing ◽  
Roughness Model ◽  
Machined Parts ◽  
Important Object

High speed milling is a newly developed advanced manufacturing technology. Surface integrity is an important object of machined parts. Surface roughness is mostly used to evaluate to the surface integrity. A theoretical surface roughness model for high face milling was established. The influence of cutting parameters on the surface roughness is analyzed. The surface roughness decreases when the cutter radius increases, total number of tooth and rotation angular speed, while it increases with the feeding velocity. The high speed face milling can get a smooth surface and it can replace the grinding with higher efficiency.

scholarly journals Fatigue Behavior of Non-Optimized Laser-Cut Medical Grade Ti-6Al-4V-ELI Sheets and the Effects of Mechanical Post-Processing

Metals ◽  
2019 ◽  
Vol 9 (8) ◽  
pp. 843 ◽  
Author(s):  
André Reck ◽  
André Till Zeuner ◽  
Martina Zimmermann
Keyword(s):  
Surface Roughness ◽  
Fatigue Strength ◽  
Surface Quality ◽  
Laser Cutting ◽  
Fatigue Behavior ◽  
Fatigue Cracks ◽  
Surface Condition ◽  
Mechanical Polishing ◽  
Fatigue Properties ◽  
Post Processing

The study presented investigates the fatigue strength of the (α+β) Ti-6Al-4V-ELI titanium alloy processed by laser cutting with and without mechanical post-processing. The surface quality and possible notch effects as a consequence of non-optimized intermediate cutting parameters are characterized and evaluated. The microstructural changes in the heat-affected zone (HAZ) are documented in detail and compared to samples with a mechanically post-processed (barrel grinding, mechanical polishing) surface condition. The obtained results show a significant increase (≈50%) in fatigue strength due to mechanical post-processing correlating with decreased surface roughness and minimized notch effects when compared to the surface quality of the non-optimized laser cutting. The martensitic α’-phase is detected in the HAZ with the formation of distinctive zones compared to the initial equiaxial α+β microstructure. The HAZ could be removed up to 50% by means of barrel grinding and up to 100% through mechanical polishing. A fracture analysis revealed that the fatigue cracks always initiate on the laser-cut edges in the as-cut surface condition, which could be assigned to an irregular macro and micro-notch relief. However, the typical characteristics of the non-optimized laser cutting process (melting drops and significant higher surface roughness) lead to early fatigue failure. The fatigue cracks solely started from the micro-notches of the surface relief and not from the dross. As a consequence, the fatigue properties are dominated by these notches, which lead to significant scatter, as well as decreased fatigue strength compared to the surface conditions with mechanical finishing and better surface quality. With optimized laser-cutting conditions, HAZ will be minimized, and surface roughness strongly decreased, which will lead to significantly improved fatigue strength.

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