Simulation and Experimental Investigation for the End Milling Process of 7075-T7451 Aluminum Alloy

2010 ◽  
Vol 97-101 ◽  
pp. 3014-3019 ◽  
Author(s):  
Cong Kang Wang ◽  
Guo Hua Qin ◽  
Dong Lu ◽  
S.Q. Xin
Keyword(s):  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Milling Force ◽  
Milling Operation ◽  
Al 7075 ◽  
Milling Forces ◽  
End Milling Process ◽  
Good Agreement ◽  
Main Factor

During the milling operation, milling forces are the main factor to cause the machining deformation of the workpiece. The flow stress of Al 7075-T7451 was first described as a function of strain, stain rate and temperature in order to obtain the true behavior in machining process. Second, a finite element method of milling process of Al 7075-T7451 was developed to obtain milling force simulations. Finally, simulated results are compared with experimental data and are shown to be in good agreement with each other.

Generalized Mechanistic Force System Model of Ball-End Milling for Sculpture Surface Machining

2001 ◽  
Author(s):  
Ismail Lazoglu
Keyword(s):  
End Milling ◽  
Mechanistic Model ◽  
Milling Process ◽  
Force System ◽  
Workpiece Surface ◽  
Surface Machining ◽  
Ball End Milling ◽  
End Milling Process ◽  
Validation Experiments ◽  
Good Agreement

Abstract In this paper, a new mechanistic model is developed for the prediction of cutting force system in ball-end milling process. The key feature of the model includes the ability to calculate the workpiece / cutter intersection domain automatically for a given cutter location (CL) file, cutter and workpiece geometries. Moreover, an analytical approach is used to determine the instantaneous chip load and cutting forces. The model also employs a Boolean approach for given cutter, workpiece geometries, and the CL file in order to determine the surface topography and scallop height variations along the workpiece surface which can be visualized in 3-D. Some of the typical results from the model validation experiments performed on Ti-6A1-4V are also reported in the paper. Comparisons of the predicted and measured forces as well as the surface topographies show good agreement.

A Simulation Study on the End Milling Operation with Multiple Process Steps of Aeronautical Frame Monolithic Components

2011 ◽  
Vol 66-68 ◽  
pp. 569-572
Author(s):  
Hai Chao Ye ◽  
Guo Hua Qin ◽  
Cong Kang Wang ◽  
Dong Lu
Keyword(s):  
End Milling ◽  
Machining Process ◽  
Deformation Analysis ◽  
Tool Paths ◽  
Milling Operation ◽  
Multiple Process ◽  
Monolithic Components ◽  
Milling Forces ◽  
The Given

Machining deformation has always been a bottleneck issue in the manufacturing field of aeronautical monolithic components. On the base of finite element method, the effect of the process steps and tool paths on the workpiece stiffness and the redistribution of residual stress in the machining process of aeronautical frame monolithic component was investigated under the given fixturing scheme. Thus, the prediction of the workpiece deformation can be carried out in reason. The proposed simulation approach to deformation analysis can be used to observe the true characteristic of milling forces and machining deformations. Therefore, the proposed method can supply the theoretical basis for the determination of the optimal process parameters.

Experimental Study on Micro End-Milling Process of Ti-6AL-4V Using Nanofluid Minimum Quantity Lubrication (MQL)

2014 ◽  
Author(s):  
Dae Hoon Kim ◽  
Pil-Ho Lee ◽  
Jung Sub Kim ◽  
Hyungpil Moon ◽  
Sang Won Lee
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
End Milling ◽  
Minimum Quantity Lubrication ◽  
Milling Process ◽  
Minimum Quantity ◽  
Nanofluid Minimum Quantity Lubrication ◽  
Micro End Milling ◽  
Milling Forces ◽  
End Milling Process

This paper investigates the characteristics of micro end-milling process of titanium alloy (Ti-6AL-4V) using nanofluid minimum quantity lubrication (MQL). A series of micro end-milling experiments are conducted in the meso-scale machine tool system, and milling forces, burr formations, surface roughness, and tool wear are observed and analyzed according to varying feed per tooth and lubrication conditions. The experimental results show that MQL and nanofluid MQL with nanodiamond particles can be effective to reduce milling forces, burrs and surface roughness during micro end-milling of titanium alloy. In particular, it is demonstrated that smaller size of nanodiamond particles — 35 nm — can be more effective to decrease burrs and surface roughness in the case of nanofluid MQL micro end-milling.

Experimental Study on Micro-Scale Milling Process Using Electro-Hydro-Dynamic (EHD) Spray Lubrication With Chilly Air

2013 ◽  
Author(s):  
Pil-Ho Lee ◽  
Dae Hoon Kim ◽  
Sang Won Lee
Keyword(s):  
End Milling ◽  
Milling Process ◽  
Burr Formation ◽  
Lubrication System ◽  
Micro Scale ◽  
Hybrid Cooling ◽  
Air Supply ◽  
Milling Forces ◽  
Cooling And Lubrication ◽  
End Milling Process

This paper investigates the characteristics of a micro-scale end-milling process using the electro-hydro-dynamic (EHD) spray lubrication with chilly air. A new hybrid cooling and lubrication system was developed by integrating EHD spray and chilly air supply modules. In the experiments, the milling forces and burr formation are observed according to varying cooling and lubrication conditions. It is demonstrated that the developed new hybrid cooling and lubrication system can reduce milling forces and burrs significantly.

Optimization of Process Parameters for Cutting Force for Aluminium 7010 in CNC End Milling Process

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
M. Kishanth ◽  
P. Rajkamal ◽  
D. Karthikeyan ◽  
K. Anand
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Optimization Of Process Parameters ◽  
Cnc End Milling ◽  
End Milling Process

In this paper CNC end milling process have been optimized in cutting force and surface roughness based on the three process parameters (i.e.) speed, feed rate and depth of cut. Since the end milling process is used for abrading the wear caused is very high, in order to reduce the wear caused by high cutting force and to decrease the surface roughness, the optimization is much needed for this process. Especially for materials like aluminium 7010, this kind of study is important for further improvement in machining process and also it will improve the stability of the machine.

Modeling & Analysis of End Milling Process Parameters Using Artificial Neural Networks

2014 ◽  
Vol 592-594 ◽  
pp. 2733-2737 ◽  
Author(s):  
G. Harinath Gowd ◽  
K. Divya Theja ◽  
Peyyala Rayudu ◽  
M. Venugopal Goud ◽  
M .Subba Roa
Keyword(s):  
Neural Networks ◽  
Artificial Neural Networks ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Artificial Neural ◽  
End Milling Process

For modeling and optimizing the process parameters of manufacturing problems in the present days, numerical and Artificial Neural Networks (ANN) methods are widely using. In manufacturing environments, main focus is given to the finding of Optimum machining parameters. Therefore the present research is aimed at finding the optimal process parameters for End milling process. The End milling process is a widely used machining process because it is used for the rough and finish machining of many features such as slots, pockets, peripheries and faces of components. The present work involves the estimation of optimal values of the process variables like, speed, feed and depth of cut, whereas the metal removal rate (MRR) and tool wear resistance were taken as the output .Experimental design is planned using DOE. Optimum machining parameters for End milling process were found out using ANN and compared to the experimental results. The obtained results provβed the ability of ANN method for End milling process modeling and optimization.

Simulation of End Milling for Weak-Rigidity Structural Parts of Aluminium Alloy in Aviation

2011 ◽  
Vol 201-203 ◽  
pp. 332-336
Author(s):  
Chun Lin Fu ◽  
Cong Kang Wang ◽  
Tie Gang Li ◽  
Wan Shan Wang
Keyword(s):  
High Speed ◽  
End Milling ◽  
Element Model ◽  
Milling Process ◽  
Milling Force ◽  
Drilling Tool ◽  
Structural Parts ◽  
Aluminum Alloy 7075 ◽  
End Milling Process ◽  
Lower Material

To resolve the problem of the parts deformation because of the milling force, a finite element model (FEM) of end milling process simulation in milling force field was established. On the base of FEM, we simulate the high-speed end milling type structure of aluminum alloy 7075 parts. We successfully predict the end milling force, obtain the effect between the upper and lower material to the milling force, and Mises stress and the tool length beyond the part.The simulation results show that the lower material can increase the milling force to upper, and upper material can decrease milling force to lower layer.The drilling tool length beyond the part is about 0.5 mm .

Experimental Study on Ball-End Milling of C/C Composite

2013 ◽  
Vol 650 ◽  
pp. 139-144
Author(s):  
Chen Wei Shan ◽  
Ying Zhao ◽  
Dong Peng Cui
Keyword(s):  
Prediction Model ◽  
High Speed ◽  
End Milling ◽  
Orthogonal Experiment ◽  
Carbon Matrix ◽  
Milling Process ◽  
Cutting Depth ◽  
Milling Force ◽  
Ball End Milling ◽  
Milling Forces

Along with the development of high speed machining technology, the ball end milling cutter’s application is more and more widely. An influence of four control parameters, namely feed, cutting depth, spindle speed and cutting width, on cutting forces is investigated. This paper focuses on experimental research of milling process of carbon fiber reinforced carbon matrix composite (C/C composite). The milling force prediction model for milling of composite using the carbide ball-end tools is built by orthogonal experiment. The experiment results show that : the reliability of the this prediction model is quite high, and the effect of milling speed on milling force is not very obvious, but the milling force increases with the increment of feed per tooth, milling depth and milling width. Using this information, a new prediction model for the milling forces is proposed that can be used for C/C composite milling.

scholarly journals Analysis of the Machining Process of Inconel 718 Parts Manufactured by Laser Metal Deposition

Materials ◽  
2019 ◽  
Vol 12 (13) ◽  
pp. 2159 ◽  
Author(s):  
Txomin Ostra ◽  
Unai Alonso ◽  
Fernando Veiga ◽  
Mikel Ortiz ◽  
Pedro Ramiro ◽  
...  
Keyword(s):  
High Performance ◽  
End Milling ◽  
Chip Morphology ◽  
Milling Process ◽  
Metal Deposition ◽  
Machining Process ◽  
Laser Metal Deposition ◽  
Aeronautical Industry ◽  
Near Net Shape ◽  
End Milling Process

Laser metal deposition (LMD) is an additive manufacturing process that allows the manufacturing of near-net-shape products. This could mean significant savings in terms of materials and costs in the manufacturing of high-performance components for the aeronautical industry. In this work, an analysis of how the LMD processing of alloy 718 affects the final machining has been carried out. For this purpose, a comparative study has been done by means of the monitoring of the end milling process of a part manufactured by LMD and a rough-milled part from forged material. Differences between process outputs such as chip morphology and cutting forces were studied. Material characteristics such as microstructure, hardness and mechanical properties were also analyzed.

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