Research on Dynamic Cutting Performance of High Speed Face Milling Cutter

2008 ◽  
Vol 375-376 ◽  
pp. 663-666
Author(s):  
Min Li Zheng ◽  
Bin Jiang ◽  
Jia Liu ◽  
Chong Yu He
Keyword(s):  
Contact Angle ◽  
Aluminum Alloy ◽  
Frequency Spectrum ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Cutting Performance ◽  
Milling Cutter

According to the characteristics of high speed face milling process, the models of dynamic cutting forces and frequency spectrum were established. By means of frequency spectrum analysis for dynamic cutting forces of high speed face milling cutter, the law of influence of cutter’s structure and parameters on dynamic cutting performance of cutter was acquired, high speed face milling cutter for machining aluminum alloy was developed, and evaluation for dynamic cutting performance of cutter was processed based on experiment. The results indicate that more teeth of cutter and greater cutting contact angle can make the energy more dispersible, higher cutting speed and greater rake of cutter can depress dynamic cutting forces, and improve effectively dynamic cutting performance of cutter. High speed face milling cutter with five teeth takes on better dynamic high speed cutting performance for machining aluminum alloy, as cutting contact angle exceeds ninety degrees but it is less than one hundred eighty degrees, and cutting speed exceeds 2260m/min.

Optimization of High Speed Milling Cutter Based on Critical Cutting Speed

2008 ◽  
Vol 392-394 ◽  
pp. 793-797
Author(s):  
Bin Jiang ◽  
Min Li Zheng ◽  
Fang Xu
Keyword(s):  
High Speed ◽  
Influencing Factor ◽  
Cutting Speed ◽  
Optimization Method ◽  
Face Milling ◽  
Cutting Performance ◽  
Feed Speed ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Cutting Heat

Based on analyses of cutting heat and temperature in high speed milling, to construct a model of critical cutting speed for high speed milling cutter, find out influencing factor of critical cutting speed, and put forward optimization method of high speed milling cutter based on critical cutting speed. The results indicate that chip conducts a majority of cutting heat along with increase of cutting speed, feed speed and the rake of cutter. Cutting heat which workpiece conducts gradually diminishes when heat source accelerates. When cutting performance of cutter satisfies requirements of high speed milling, the proportion of cutting heat which workpiece conducts approaches its maximum as cutting speed comes to critical cutting speed. To optimize high speed face milling cutter for machining aluminum alloy according to critical cutting speed, the cutter takes on better cutting performance when cutting speed is 2040m/min~2350m/min.

Research on High Speed Face Milling Cutter Based on the Model of Stress Field

2006 ◽  
Vol 532-533 ◽  
pp. 341-344 ◽  
Author(s):  
Min Li Zheng ◽  
Bin Jiang ◽  
Bin Hu Chen ◽  
Yong Jun Sun
Keyword(s):  
Stress Field ◽  
High Speed ◽  
Milling Process ◽  
Face Milling ◽  
Cutting Performance ◽  
Field Analysis ◽  
Element Analysis ◽  
Milling Cutter ◽  
High Speed Cutting ◽  
Zero Degree

According to the characteristics of high speed face milling process, the models of the stress field for high speed face milling cutter with two sorts of structure are proposed and established. By means of the finite element analysis of the stress field for high speed face milling cutters, the law of influence of the cutter’s structure, the cutter’s subassemblies and the fixing rake of inserts on the stress field of cutter is acquired under the action of high rotate speed. In this foundation, the model reconstruction and the stress field analysis of the cutter are completed, and the model of evaluation for dynamic cutting performance of high speed face milling cutter is established. The results of high speed face milling experiment and frequency spectrum analysis of dynamic cutting force of the cutter indicate that high speed face milling cutter with the fixing rake of zero degree and less subassemblies takes on better dynamic high speed cutting performance.

scholarly journals Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

2021 ◽  
pp. 71-84
Author(s):  
Nhu-Tung Nguyen ◽  
Dung Hoang Tien ◽  
Nguyen Tien Tung ◽  
Nguyen Duc Luan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
High Speed Milling

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

Safety Prediction of High Speed Face Milling Cutter with Indexable Inserts

2008 ◽  
Vol 375-376 ◽  
pp. 593-597
Author(s):  
Bin Jiang ◽  
Min Li Zheng ◽  
Fang Xu ◽  
Ya Guang Li
Keyword(s):  
Aluminum Alloy ◽  
Rotational Speed ◽  
High Speed ◽  
Cutting Speed ◽  
Element Model ◽  
Face Milling ◽  
Field Analysis ◽  
Milling Cutter ◽  
Strength Failure ◽  
Loads Analysis

Based on loads analysis and failure analysis for high speed face milling cutter with indexable inserts, the failure criterion of cutter was propounded, and the finite element model of cutter was established. By means of modal analysis and stress field analysis, the law of influence of the structure and elements of cutter on the safety of cutter was acquired, high speed face milling cutter for machining aluminum alloy was developed. According to ISO15641 international standard, safety prediction of cutter and experiments were completed. The results indicate that rigidity failure rotational speed is higher strength failure rotational speed of high speed face milling cutter, connection strength between cutter body and screw bolt affects directly the safety rotational speed of cutter. High speed face milling cutter for machining aluminum alloy possesses higher safety and better dynamic milling performance as cutting speed is less than 2820m/min.

Experimental Study of Cutting Performance and Tool Wear in Dry Side Milling of Aluminum Alloy with DLC-Coated HSS-Co Cutter

2012 ◽  
Vol 523-524 ◽  
pp. 64-69
Author(s):  
Yoshio Mizugaki ◽  
Kazuki Takafuji ◽  
Koichi Kikkawa ◽  
Teppei Kuroda ◽  
Taro Kimura
Keyword(s):  
Aluminum Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Experimental Results ◽  
Steel Matrix ◽  
Milling Cutter ◽  
Side Milling ◽  
Radial Depth

This paper presents the experimental results of cutting performance and tool wear of a milling cutter in dry side milling of aluminum alloy A2017. The milling cutter consists of Co-bonded High-Speed-Steel matrix with Diamond-Like-Carbon coating (abbrev. DLC-coated HSS-Co cutter). The machining experiments were carried out under cutting speed of 63 to 189 [m•min-1] and feed of 0.08 [mm/tooth/rev], and the criterion of tool life was the generation of gauge and/or scratch on a machined surface. The experimental results support that the DLC-coated cutter in up cutting has good performance among four types of combination by the presence or absence of coating and the up/down cutting manner. They also showed that the tool life of DLC-coated cutter in up cutting under cutting speed of 157 [m•min-1] was corresponding to the cutting distance of 80 [m] with average width of flank wear 102 [μm] and that in down cutting was 60 [m] with 85 [μm]. In the range of cutting distance up to 100 [m], the resultant cutting force with the DLC-coated cutter was smaller than that with a non-coating cutter. In case of the DLC-coated cutter in up cutting under the cutting speed of 189 [m•min-1], a chatter vibration occurred during the initial cutting distance. In case of the radial depth of cut of 1.5 [mm], it lasted up to the cutting distance of 10 [m] and more.

An Experiment-Based Investigation on Characteristic and Model of Milling Forces during End-Milling Aluminum Alloy

2014 ◽  
Vol 494-495 ◽  
pp. 602-605
Author(s):  
Zeng Hui An ◽  
Xiu Li Fu ◽  
Ya Nan Pan ◽  
Ai Jun Tang
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
End Milling ◽  
Influence Factors ◽  
Cutting Speed ◽  
Cutting Depth ◽  
Milling Forces

Cutting forces is one of the important physical phenomena in metal cutting process. It directly affects the surface quality of machining, tool life and cutting stability. The orthogonal experiments of cutting forces and influence factors with indexable and solid end mill were accomplished and the predictive model of milling force was established during high speed end milling 7050-T7451 aluminum alloy. The paper makes research mainly on the influence which the cutting speed, cutting depth and feed have on the cutting force. The experimental results of single factor showed that the cutting forces increase earlier and drop later with the increase of cutting speed, and the cutting speed of inflexion for 7050-T7451 is 1100m/min. As axial cutting depth, radial cutting depth and feed rate increase, the cutting force grows in different degree. The cutting force is particularly sensitive to axial cutting depth and slightly to the radial cutting depth.

Modeling and Prediction of Cutting Noise in the Face-Milling Process

2007 ◽  
Vol 129 (3) ◽  
pp. 527-530 ◽  
Author(s):  
Karthikeyan Sampath ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Aerodynamic Noise ◽  
Noise Prediction ◽  
Vibration Data ◽  
Total Noise ◽  
Workpiece Vibration ◽  
The Face

A cutting noise prediction model is developed to relate the cutter-workpiece vibrations to the sound pressure field around the cutter in the high-speed face-milling process. The cutter-workpiece vibration data are obtained from a dynamic mechanistic face-milling force simulation model. The total noise predicted, based on both cutting noise and aerodynamic noise prediction, compares well to the noise observed experimentally in the face-milling process. Using the model, the effects of various machining and cutter geometry parameters are studied. It is shown that cutter geometry, machine dynamics, and cutting speed all play important roles in determining overall noise in face milling.

Experimental study on the chip morphology, tool–chip contact length, workpiece vibration, and surface roughness during high-speed face milling of A6061 aluminum alloy

2019 ◽  
Vol 234 (3) ◽  
pp. 610-620 ◽  
Author(s):  
Thi-Hoa Pham ◽  
Duc-Toan Nguyen ◽  
Tien-Long Banh ◽  
Van-Canh Tong
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Contact Length ◽  
Face Milling ◽  
Cutting Conditions ◽  
Workpiece Vibration

In this study, experiments of high-speed face milling of A6061 aluminum alloy with a carbide insert milling cutter under dry cutting conditions were conducted. The contact length between tool and chip, the workpiece vibration amplitude, and the arithmetic average surface roughness were measured under varying cutting conditions (cutting speed, feed rate, and depth of cut). The characteristics of chip morphology were observed using scanning electron microscope. Experimental results showed that the increasing cutting speed reduced the tool–chip contact length, the workpiece vibration, and the surface roughness. The tool–chip contact length, the workpiece vibration, and the surface roughness were all increased with increasing cutting depth and feed rate. The results of chip morphology showed that the chips with serrated form were generated under high-speed cutting conditions. Moreover, scratch lines, plastic deformation cavities, and local molten chip material were observed on the slide chip surface.

Surface Integrity Analysis on High Speed End Milling of 7075 Aluminum Alloy

2012 ◽  
Vol 426 ◽  
pp. 321-324 ◽  
Author(s):  
X.J. Cai ◽  
Wei Wei Ming ◽  
Ming Chen
Keyword(s):  
Aluminum Alloy ◽  
Surface Integrity ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Stress Profile ◽  
Residual Stress Profile ◽  
Aerospace Manufacturing ◽  
Integrity Analysis

Surface integrity is a significant issue concerning machined part quality, especially for aluminum milling process in aerospace manufacturing. This paper gave an intensive analysis on surface integrity in high speed milling of 7075-T651 aluminum alloy, and the relationships of surface topography, surface roughness and residual stress profile with cutting speed at high levels were discussed and some basic aspects concerning surface integrity in high speed end milling of aluminum parts were presented.

Simulation on Cutting Temperature during High-Speed Milling Aluminum Alloy 7055

2013 ◽  
Vol 328 ◽  
pp. 486-490 ◽  
Author(s):  
Liang Tan ◽  
Chang Feng Yao ◽  
Wei Zuo ◽  
Dao Xia Wu
Keyword(s):  
Aluminum Alloy ◽  
Theoretical Basis ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Element Model ◽  
Milling Process ◽  
High Speed Milling ◽  
Milling Parameters

To optimize the parameters of high-speed milling of aluminum alloy 7055 and provide a theoretical basis for cutting temperature control, a finite element model of high-speed milling process of aluminum alloy 7055 was developed with AdvantEdge. Based on these models, the effect of milling parameters on cutting temperature is investigated by single factor experiments. And the temperature distribution of workpiece and cutting tool is predicted. The results show that the highest temperature occurs at close to the tool tip in the rack face, the temperature increases with an increase in cutting speed and feed per tooth, while other parameters have a less significant effect on cutting temperature.

Sign in / Sign up

Export Citation Format

Share Document