Effect of Milling Parameters on Surface Roughness for High-Speed Milling of Pre-Sintering Zirconia

2014 ◽  
Vol 988 ◽  
pp. 253-256
Author(s):  
Jun Wei Liu ◽  
Xiao Jun Yang
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
High Hardness ◽  
Relative Sensitivity ◽  
Stability Domain ◽  
Milling Process ◽  
Spindle Speed ◽  
Dental Restoration ◽  
Milling Parameters ◽  
Main Factor

Zirconia has been widely concerned in dental restoration duo to its excellent properties, but its high hardness make direct milling inefficient, while pre-sintering zirconia has good machinability. By single factor experiment in high-speed finish milling on 900°C pre-sintering zirconia, effect of four milling process parameters’ change on surface roughness was analyzed, and process sensitivity and relative sensitivity were put forward to compare the effect degree and to optimize milling parameters’ domains respectively. Roughness models are established on each parameter, and analysis results show the effect degree in order of spindle speed, feed engagement, cutting width, and cutting depth, spindle speed in them is a main factor. Based on relative sensitivity, milling parameters stability domain and instability domain are presented.

scholarly journals Effect of High Speed Milling Process Parameters on the Milling Force and Surface Topography of AM50A Magnesium Alloy

2018 ◽  
Vol 36 (1) ◽  
pp. 124-131
Author(s):  
Hongji Zhang ◽  
Yuanyuan Ge ◽  
Hong Tang ◽  
Yaoyao Shi ◽  
Zengsheng Li
Keyword(s):  
Magnesium Alloy ◽  
Surface Quality ◽  
High Speed ◽  
Milling Process ◽  
Spindle Speed ◽  
Feed Speed ◽  
Milling Force ◽  
High Speed Milling ◽  
Milling Parameters

Within the scope of high speed milling process parameters, analyzed and discussed the effects of spindle speed, feed rate, milling depth and milling width on milling forces in the process of high speed milling of AM50A magnesium alloy. At the same time, the influence of milling parameters on the surface roughness of AM50A magnesium alloy has been revealed by means of the measurement of surface roughness and surface micro topography. High speed milling experiments of AM50A magnesium alloy were carried out by factorial design. Form the analysis of experimental results, The milling parameters, which have significant influence on milling force in high speed milling of AM50A magnesium alloy, are milling depth, milling width and feed speed, and the nonlinear characteristics of milling force and milling parameters. The milling force decreases with the increase of spindle in the given mill parameters. For the effects of milling parameters on surface quality of the performance, in the milling depth and feeding speed under certain conditions with the spindle speed increases the surface quality of AM50A magnesium alloy becomes better with the feed speed increases the surface quality becomes poor. When the spindle speed is greater than 12000r/min, the milling depth is less than 0.2mm, and the feed speed is less than 400mm/min, the milling surface quality can be obtained easily.

Predictive Model of Surface Roughness in High-Speed End Milling Process by Factorial Design of Experiments

2007 ◽  
Vol 339 ◽  
pp. 189-194
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao
Keyword(s):  
Surface Roughness ◽  
Design Of Experiments ◽  
Factorial Design ◽  
High Speed ◽  
End Milling ◽  
Milling Process ◽  
Regression Coefficients ◽  
Milling Parameters ◽  
Factorial Design Of Experiments ◽  
End Milling Process

Predictive models are presented for the surface roughness in high-speed end milling of 0.45%C steel and P20 die-mould steel based on statistical test and multiple-regression analysis. The data for establishing model is derived from experiments conducted on a high-speed machining centre by factorial design of experiments. The significances of the regression equation and regression coefficients are tested in this paper. The effects of milling parameters on surface roughness are investigated by analyzing the experimental curves.

scholarly journals Stability Analysis of Milling Process with Variable Spindle Speed and Pitch Angle considering Helix Angle and Process Phase Difference

2021 ◽  
Vol 2021 ◽  
pp. 1-15
Author(s):  
Gang Jin ◽  
Haotian Jiang ◽  
Jianxin Han ◽  
Zhanjie Li ◽  
Hua Li ◽  
...  
Keyword(s):  
Phase Difference ◽  
Pitch Angle ◽  
High Speed ◽  
Helix Angle ◽  
Stability Domain ◽  
Milling Process ◽  
Spindle Speed ◽  
The Stability ◽  
The Time Domain ◽  
Milling Chatter

Suppression of milling chatter by disrupting regenerative effect is a well-known method to obtain higher cutting stability domain. In this paper, a dynamic model of the milling process with variable spindle speed and pitch angle considering helix angle and process phase difference is presented. Then, an updated semidiscretization method is applied to obtain the stability chart. After the effectiveness of the proposed method is confirmed by comparisons with the previously published works and the time-domain simulations, lots of analyses are conducted to deeply evaluate the influence of the helix angle, the process phase difference, and feed per tooth on milling stability. Results show that the change of helix angle can result in significant stability discrepancies for both high-speed and low-speed regions. Though the process phase difference has the randomness and immeasurability in the practical application, it has an important influence on the stability and will result in a periodic evolution of the stability with a period π. Also, its recommended values are given for the practical milling process.

Prediction of Surface Roughness of Mild Steel Alloy in CNC Milling Process Using ANN and GA Technique

2020 ◽  
Vol 38 (12A) ◽  
pp. 1842-1851
Author(s):  
Hind H. Abdulridha
Keyword(s):  
Neural Network ◽  
Surface Roughness ◽  
Artificial Neural Network ◽  
Milling Process ◽  
Spindle Speed ◽  
Steel Alloy ◽  
Milling Parameters ◽  
Artificial Neural ◽  
Artificial Neural Network Ann ◽  
Tool Diameter

In this paper, Analysis Of Variance (ANOVA), Artificial Neural Network (ANN), and Genetic Algorithm (GA) have been studied to predict the effect of milling parameters on the Surface Roughness (Ra) during machining of mild steel alloy. The milling experiments carried out based on the Taguchi design of experiments method using (L16) orthogonal array with 3 factors and 4 levels. The influence of three independent variables such as spindle speed (910, 930, 960, and 1000 rpm), feed rate (93, 95, 98, and 102 mm/min), and Tool Diameter (8, 10, 12, and 14 mm) on the Surface Roughness (Ra) were tested and analyzed with (ANOVA) to predict the response which indicates that spindle speed was the most significant factor effecting on Surface Roughness (Ra). Artificial Neural Network (ANN) and numerical methods are used widely for modeling and predict the performance of manufacturing technologies. Neural Network technique with 2 hidden layers, 10 neurons size, 1000 epochs, and Trainlm transfer function is used to predict the result. The Genetic Algorithm (GA) has been utilized to find optimal cutting conditions during a milling process. From the results, the optimal value of spindle speed is (930 rpm), feed-rate is (95 mm/min) and tool diameter is (8 mm). This network structure is capable of predicting the Surface Roughness (Ra) well to optimize the milling parameters. Artificial Neural Network (ANN) predicted results indicate good agreement between the experimental and the predicted values.

Investigation of Surface Roughness and Material Removal Rate for High Speed Micro End Milling on PMMA

2015 ◽  
Vol 1115 ◽  
pp. 12-15
Author(s):  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
Abdul Rahman Mohamed ◽  
Md. Sazzad Hossein Chowdhury
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
High Speed ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Micro End Milling

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

Effect of Surface Roughness and Residual Stress Induced by High Speed Milling Process on Short Crack Growth

2016 ◽  
Author(s):  
B. Zheng ◽  
H. D. Yu ◽  
X. Wang ◽  
X. M. Lai
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Residual Stresses ◽  
Crack Growth ◽  
Damage Evolution ◽  
High Speed ◽  
Milling Process ◽  
Short Crack ◽  
Machining Process ◽  
Effect Of Surface

Surface scratches and residual stresses inevitably appear on the surface of the component as a result of the machining process. The damage evolution of surface scratch due to the combined effect of cyclic loading and residual stresses will be significantly different from the case where only the cyclic loading is considered. In the damage evolution of surface scratch, the short crack growth is of great importance owing to its apparently anomalous behaviors compared with the long-crack growth. In this paper, the effect of the surface roughness and the residual stress on the short crack growth is studied. Firstly, the surface roughness and the residual stress of 7075-T6 aluminum alloy induced by the high speed milling process with various cutting speeds and feed rates are investigated with the experimental method. The maximum height roughness parameter is measured, which is regarded as the surface defect induced by the milling process. The residual stress on the specimen surface is measured with the X-ray diffraction. Results show that the surface roughness becomes higher with the increase of the feed rate. However, the influence of the cutting speed on the surface roughness is not significant. The residual stresses on the specimen surface are all in the compressive state. The residual stress is more compressive as the feed rate increases. The effects of the process parameters on the surface roughness and the residual stress are described by the fitted formulas. Then a modified model is built to characterize short fatigue crack growth behaviors with the consideration of the residual stress. This model is proved to provide a realistic treatment of the short crack growth, as reflected by comparison with experimental fatigue crack growth data of medium carbon steel and 7075-T6 aluminum alloy published in literature. The effect of surface roughness and residual stress caused by the milling process on the short crack growth is also investigated by using the proposed model. The growth of the scratch is nonlinear when it is subjected to the cyclic load. The compressive residual stress reduces the growth rate of the crack. The crack with larger initial surface roughness grows faster than that with smaller roughness. The correlation of surface roughness, residual stress and crack growth length is obtained by the polynomial fitting. The investigations in this paper can help the damage tolerance design of structures and improve the awareness of the effect of the residual stress and surface roughness induced by the machining process on the short crack growth.

Tool Vibration due to High Speed Micro End Milling Parameters

2013 ◽  
Vol 372 ◽  
pp. 364-368 ◽  
Author(s):  
Abdul Rahman Mohamed ◽  
Nur Atiqah ◽  
Mohammad Yeakub Ali ◽  
M.S.H. Chowdhury
Keyword(s):  
High Speed ◽  
End Milling ◽  
Signal To Noise Ratio ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Signal To Noise ◽  
Tool Vibration ◽  
Milling Parameters ◽  
Micro End Milling

This paper presents the effect of high speed micro end milling parameters on tool vibration during machining of poly (methyl methacrylate) (PMMA). The main focus is to achieve minimum tool vibration by controlling the cutting parameters; spindle speed, feed rate and depth of cut. An empirical model for tool vibration has been developed using Taguchi method. The orthogonal array, signal-to-noise ratio and analysis of variance revealed that high spindle speed is the most influential parameter to increase the level of tool vibration.

A Study of the Sensitivity of Parameters Affecting Surface Roughness in High Speed Milling Superalloy GH4169

2013 ◽  
Vol 711 ◽  
pp. 143-148 ◽  
Author(s):  
Wei Wei Liu ◽  
Xu Sheng Wan ◽  
Xiao Yan Li ◽  
Yuan Yu ◽  
Dong Fang Wang
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Orthogonal Experiment ◽  
Relative Sensitivity ◽  
Depth Of Cut ◽  
High Temperature Alloy ◽  
High Speed Milling ◽  
Genetic Algorithm Method ◽  
Coated Carbide ◽  
Carbide Inserts

The orthogonal experiment is processed for high-speed milling superalloy GH4169 with TiAlN coated carbide inserts. The empirical formula of the surface roughness is acquired by using Genetic Algorithm method. On the basis of this formula, studying the absolute sensitivity and relative sensitivity of surface roughness for milling speed, depth of cut and feed; The results showed that in the process of high-speed milling of high-temperature alloy GH4169, Surface roughness is most sensitive to the change of milling feed; change of milling depth take second place and milling speed is the least sensitive.

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