Chip Formation in High-Speed Milling of Titanium Alloy with PCD Tools

2014 ◽  
Vol 800-801 ◽  
pp. 150-154 ◽  
Author(s):  
An Hai Li ◽  
Jun Zhao ◽  
Hong Guo Zheng ◽  
Yong Hong Lu
Keyword(s):  
Free Surface ◽  
Chip Formation ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Sharp Decrease ◽  
Water Soluble ◽  
Cutting Fluid ◽  
High Speed Milling ◽  
Pcd Tools

This paper presents a detailed analysis of chip morphology through an experimental study of high-speed milling of Ti-6Al-4V alloy with PCD tools. Milling tests were conducted for cutting speed range from 125 m/min to 2000 m/min with water-soluble cutting fluid. The collected chips were firstly examined with a digital cameras and the free surface of the chips was analyzed by a scanning electron microscope (SEM). Geographical parameters of chip morphologies were described in saw-tooth/lamella frequency on the free surface and chip width. Experimental results show that the variation of chips in high-speed end milling of Ti-6Al-4V alloy is as follows, long and straight-shaped → spiral-shaped → curly-shaped → irregular-shaped. The free surface of chips exhibits saw-tooth lamella structures. The lamella becomes clearer and more obvious at higher cutting speeds. Within the same measurement distance, there is a sharp decrease in the lamella number within same measuring range. This should be attributed to the enhancement of the thermal mechanical coupled field applied to the chip formation processes.

Study on Finite Element Simulation of the Influence of Cutting Speed on Chip Formation of SiCpAl Composites in High Speed Milling

2014 ◽  
Vol 800-801 ◽  
pp. 290-295
Author(s):  
Chuang Liu ◽  
Shu Tao Huang ◽  
Ke Ru Jiao ◽  
Li Fu Xu
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Speed ◽  
High Volume ◽  
High Volume Fraction ◽  
High Speed Milling ◽  
Finite Element Software ◽  
High Efficient

Application prospect of the high volume fraction SiCp/Al composites becomes increasingly widespread, the study of cutting mechanism is important for achieving its high efficient and precision machining. In this paper, a three-dimensional beveled simulation model of high volume fraction SiCp/Al composites on high-speed milling is established by finite element software ABAQUS, the constitutive on model material, the tool-chip contact and the chip separation model is elected reasonably.The paper analyzes the effect of cutting speed on the chip formation and the stress distribution of the material. The results shows that: with the increasing of cutting speed, the chip is easily broken, cutting speed have little impact on the maximum stress of the material.

Investigation of Chip Morphology in High-Speed Milling of Nickel-Based Superalloy GH706

2014 ◽  
Vol 800-801 ◽  
pp. 113-118
Author(s):  
Sheng Lei Xiao ◽  
Xian Li Liu ◽  
Yu Wang ◽  
Kai Li
Keyword(s):  
Chip Formation ◽  
High Speed ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Adiabatic Shear ◽  
Shear Instability ◽  
Serrated Chip ◽  
High Speed Milling ◽  
Nickel Based Superalloy ◽  
Serrated Chip Formation

This paper analyzed the serrated chip formation process and mechanism in high-speed milling of nickel-based superalloy GH706. Firstly, analyzed two theories of serrated chip formation: cyclical fracture theory and adiabatic shear theory. Secondly, used the simulation of chip formation in high-speed milling of GH706 process, and concluded that the two major theories have achieved dialectical unity when machining for such difficult machining materials. Finally experiments for serrated chip, when cutting speed exceeded 200/min, serrated chips became more obvious. Research has shown that for nickel-based superalloy, adiabatic shear instability of the unstable thermoplastic in the first deformation zoon become the leader of formation of serrated chip, followed as the speed increases, fracture aggravate the degree of serrated chip.

Effect of Various Cooling Strategies on Surface Roughness of High Speed Milling Ti-6Al-4V

2011 ◽  
Vol 697-698 ◽  
pp. 49-52 ◽  
Author(s):  
Xiao Yong Yang ◽  
Cheng Zu Ren ◽  
Guang Chen ◽  
Bing Han ◽  
Y. Wang
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Side Milling ◽  
High Speed Milling ◽  
Cooling Strategies ◽  
Radial Depth

This study focused on the side milling surface roughness of titanium alloy under various cooling strategies and cutting parameters. The experimental results show that the cooling strategies significantly affect the surface roughness in milling Ti-6Al-4V. Surface roughness (Ra) alterations are investigated. Cutting fluid strategy made nearly all the smallest and most stable roughness values. The surface roughness values produced by all cooling strategies are obviously affected by feed, radial depth-of-cut and cutting speed. However, axial depth-of-cut has little influence.

Investigation on the Cutting Force of High-Speed Milling of High Volume Fraction of SiCp/Al Composites with PCD Tools

2013 ◽  
Vol 873 ◽  
pp. 350-360
Author(s):  
Song Peng ◽  
Li Jing Xie ◽  
Xi Bin Wang ◽  
Na Xin Fu ◽  
Xing Kuan Shi
Keyword(s):  
Response Surface Methodology ◽  
Cutting Force ◽  
Response Surface ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Cutting Depth ◽  
Milling Force ◽  
High Speed Milling ◽  
Pcd Tools

High-speed milling tests for 65vol.%SiCp/6063Al composites were performed by polycrystalline diamond (PCD) tools, response surface methodology was utilized in this study, and a cutting force model was developed through response surface methodology, which contained some important parameters such as cutting speed, cutting feed rate, cutting depth and cutting width. The analysis of variance (ANOVA) indicated that the proposed mathematical model can adequately describe the relationship between cutting force and cutting process parameters. The results show that cutting depth is the biggest important factor of milling force, and cutting feed rate is the second important factor, cutting speed is the third; milling force would not increase with the increasing of cutting width.

High-Speed Photographic Study of Chip Formation during End Milling of GFRP Composites

2013 ◽  
Vol 845 ◽  
pp. 915-919 ◽  
Author(s):  
Azwan I. Azmi ◽  
R.J.T. Lin ◽  
D. Bhattacharyya
Keyword(s):  
Chip Formation ◽  
High Speed ◽  
End Milling ◽  
Fibre Orientation ◽  
Cutting Speed ◽  
Video Camera ◽  
High Speed Photography ◽  
Forming Process ◽  
High Speed Video Camera ◽  
Glass Fibre Reinforced Composites

The chip forming process during end milling of glass fibre reinforced composites has been investigated in this study. The qualitative results from a high speed video camera has showed that discontinuous and fracturing of chips has been created due to the heterogeneity and insufficient ductility of the composite materials. The high-speed photography footage has also disclosed that a layer of delaminated chip can be formed as the tool cutting edge fractured the workpiece along the fibre orientation. The fracture of chips into smaller segments accelerated as the cutting speed increases. Likewise, shorter fragment of chips were created as the tool cut at different fibre orientation or angle. This makes it difficult to denote any chip formation processes during the end milling experiments.

Simulation of High Speed Milling of SiCp/Al Metal Matrix Composites Based on Deform

2013 ◽  
Vol 589-590 ◽  
pp. 100-105
Author(s):  
Ke Ru Jiao ◽  
Shu Tao Huang ◽  
Li Fu Xu ◽  
Li Zhou
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Transient Temperature ◽  
Matrix Composites ◽  
High Speed Milling ◽  
Pcd Tools

By 3D finite element simulation for temperature field and tool wear of SiCp/Al metal matrix composites under the condition of high speed milling, we draw a conclusion that the most significant influence on cutting temperature is cutting speed, less is feed rates, the minimum is cutting depth, which is exactly the same as the influence law of ordinary metal cutting. In the course of high-speed milling SiCp/Al by PCD tools, the higher the cutting speed is, the bigger wearing depth of tools is. When v=300m/min, ap=0.5 mm, f=0.3 mm/r, the transient temperature in the milling would reach to 619°C. Such a high temperature can cause graphitizing wear of the PCD tools. Because of the effectiveness of the simulation’s conclusion, it is vital significance to the reasonable options of cutting parameters and the prolongation of tool life.

Research on Instantaneous Cutting Force of High Speed Ball-End Milling Cutter

2011 ◽  
Vol 188 ◽  
pp. 277-282 ◽  
Author(s):  
Chang Xing Qi ◽  
Bin Jiang ◽  
Min Li Zheng ◽  
Y.J. Yang ◽  
P. Sun
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Process ◽  
Energy Concentration ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Ball End Milling ◽  
The Impact

For the instability of ball-end milling cutter in high speed milling, instantaneous cutting process of high speed milling hardened steel was studied. The model of instantaneous cutting layer parameters of high speed ball-end cutter was established, and the influence of cutting speed and inclination angles on instantaneous cutting layer parameters were obtained. Using the model, instantaneous cutting force was studied, and high speed milling experiment was processed. Results show that the increase of cutting speed makes the change rate of cutting layer parameters increasing, leads to the energy concentration in cutting process, and increases the impact on milling cutter. The increase of inclination angle makes the instantaneous cutting layer parameters show a trend of decrease and the decrease of cutting thickness more rapidly, which caused instantaneous unit cutting force to increase and the instantaneous main cutting force appears increasing trend, and the cutting process become unstable.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

Sign in / Sign up

Export Citation Format

Share Document