Milling Force Analysis and Modeling of Super-Alloy GH2132

2016 ◽  
Vol 836-837 ◽  
pp. 99-105
Author(s):  
Qing Yu Wu ◽  
Lei He ◽  
Hu Xiao ◽  
Liang Li
Keyword(s):  
Cutting Force ◽  
Orthogonal Experiment ◽  
Linear Regression Analysis ◽  
Multiple Linear Regression Analysis ◽  
Good Prediction ◽  
Cutting Depth ◽  
Milling Force ◽  
Machine Material ◽  
Specific Cutting Force ◽  
Good Prediction Accuracy

Iron-based alloy GH2132 is a kind of difficult-to-machine material. In this study, the experiments were processed to research the effect of feed per tooth, axial cutting depth and radial cutting depth on milling force. Variance analysis was made on the three factors. The results reveal that axial cutting depth affects milling force significantly, followed by feed per tooth and radial cutting depth has little influence on it. Two types of empirical model of milling force were established by the result of orthogonal experiment and multiple linear regression analysis. It was verified that both (hm, ap) model and (hm, ap, ae) model had good prediction accuracy compared with the experimental data. By calculating specific cutting force using the (hm, ap) model, a modified coefficient of the specific cutting force for 1mm2 chip cross section was proposed. The study would provide guidance to improve the machining precision and machining efficiency of high temperature alloy materials.

Stability Analysis on Milling Processing of Aviation Aluminum Alloy

2013 ◽  
Vol 670 ◽  
pp. 228-234
Author(s):  
Wei Hua Wu ◽  
Y.Y. Guo ◽  
C. Zhao
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Stress Condition ◽  
Orthogonal Experiment ◽  
Thin Wall ◽  
Cutting Depth ◽  
Force Coefficient ◽  
Milling Force ◽  
Four Levels ◽  
Thin Wall Part

Based on milling experiment to explore the transformation and stress condition in the process of cutting of the thin-wall part made by aviation aluminum alloy, and then get data from the milling experiment through altering the axial cutting depth Ap=1 mm (a=1 mm), cutting radius Ae, spindle speed n and feed per tooth for milling force fz. Considering the milling force coefficient affected by each milling parameters, the orthogonal experiment of four factors and four levels are designed, and the milling coefficient is solved by MATLAB. The results indicates that the axial cutting depth Ap=1 mm (a=1 mm), the cutting force Fx increases with increasing in feedrate per tooth fz (c). the feedrate per tooth fz=0.03 mm (c=0.03 mm), the cutting force Fx increases with increasing in the axial cutting depth Ap. The discipline that the milling coefficient has an influence on milling force is obtained from the research which can provide the reference on the purpose of optimizing milling coefficient.

Investigation of the Milling Performance about 7050-T7451 Aluminum Alloy Based on Orthogonal Experiment

2011 ◽  
Vol 121-126 ◽  
pp. 1431-1435
Author(s):  
Ke Yan Tang ◽  
Li Hua Zhou ◽  
Li Song
Keyword(s):  
Aluminum Alloys ◽  
High Speed ◽  
Orthogonal Experiment ◽  
Linear Regression Analysis ◽  
Multiple Linear Regression Analysis ◽  
Milling Process ◽  
Empirical Formulas ◽  
Milling Force ◽  
High Speed Milling ◽  
Orthogonal Experiments

The high-speed milling process has been widely used for manufacturing the aeronautical aluminum alloys. And it is quite important to choose the logical milling parameters for improving the precision and surface quality in the high-speed milling aluminum alloys. In this paper, the orthogonal experiments are designed and made to construct the relationships between the milling force and milling factors to 7050-T7541 aluminum alloys. The milling factors are mainly consist of the milling speed, the feed rate, the milling depth and the milling width. The empirical formulas of milling force are derived by multiple linear regression analysis, and the formulas are tested to be correct by the single factor experiment. The research is very important for further study of the aluminum alloys.

Simulation of Machining of Incoloy 907 Based on Thermodynamical Constitutive Equation

2013 ◽  
Vol 631-632 ◽  
pp. 681-685
Author(s):  
Fang Shao ◽  
Fa Qing Li ◽  
Hai Ying Zhang ◽  
Xuan Gao
Keyword(s):  
Cutting Force ◽  
Cutting Temperature ◽  
Tool Material ◽  
High Reactivity ◽  
Good Prediction ◽  
Workpiece Material ◽  
Element Analysis ◽  
Good Prediction Accuracy ◽  
Experimental Cutting ◽  
Cutting Tool Materials

Aero-engine alloys (also as known as superalloys)are known as difficult-to-machine materials, especially at higher cutting speeds, due to their several inherent properties such as low thermal conductivity and their high reactivity with cutting tool materials. In this paper a finite element analysis (FEA) of machining for Incoloy907 is presented. In particular, the thermodynamical constitutitve equation(T-C-E) in FEA is applied for both workpiece material and tool material. Cutting temperature and cutting force are predicted. The comparison between the predicted and experimental cutting temperature and cutting force are presented and discussed. The results indicated that a good prediction accuracy of both principal cutting temperature and cutting force can be achieved by the method of FEA with thermodynamical constitutitve equation.

Simulation of Machining of Incoloy 907 with Thermodynamical Constitutive Equation

2013 ◽  
Vol 634-638 ◽  
pp. 1790-1793
Author(s):  
Fang Shao ◽  
Hai Ying Zhang ◽  
Zhi Jun Fan
Keyword(s):  
Cutting Force ◽  
Cutting Temperature ◽  
Tool Material ◽  
High Reactivity ◽  
Good Prediction ◽  
Workpiece Material ◽  
Element Analysis ◽  
Good Prediction Accuracy ◽  
Experimental Cutting ◽  
Cutting Tool Materials

Aero-engine alloys (also as known as superalloys)are known as difficult-to-machine materials, especially at higher cutting speeds, due to their several inherent properties such as low thermal conductivity and their high reactivity with cutting tool materials. In this paper a finite element analysis (FEA) of machining for Incoloy907 is presented. In particular, the thermodynamical constitutitve equation(T-C-E) in FEA is applied for both workpiece material and tool material. Cutting temperature and cutting force are predicted. The comparison between the predicted and experimental cutting temperature and cutting force are presented and discussed. The results indicated that a good prediction accuracy of both principal cutting temperature and cutting force can be achieved by the method of FEA with thermodynamical constitutitve equation.

The Research on Milling Force in High-Speed Milling Nickel-Based Superalloy of Inconel 718

2013 ◽  
Vol 395-396 ◽  
pp. 1031-1034
Author(s):  
Can Zhao ◽  
Yu Bo Liu
Keyword(s):  
Cutting Force ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Depth ◽  
Milling Force ◽  
High Speed Milling ◽  
Nickel Based Superalloy ◽  
Cutting Speeds

This paper makes an experiment in high-speed milling of Inconel 718. Cutting tests were performed using round and ceramic tools, at feeds from 0.06 to 0.14 mm/tooth, Axial Depth of Cut from0.5 to 1.5mm,and cutting speeds ranging from 500 to 1037 m/min. The behaviour of the cutting forces during machining was then measure. The results show that cutting force increases first and then decreases with the increase of feed per tooth, the tool chipping and groove wear were found with the increase of axial cutting depth, and cutting force is increased; the increase in cutting force with the cutting speed increases, when the cutting speed reaches a critical speed, the cutting force as the cutting speed increases began to decline.

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.

Simulation of Machining of Incoloy 907 Based on Thermodynamics

2014 ◽  
Vol 800-801 ◽  
pp. 374-379
Author(s):  
Fang Shao ◽  
Yu Ting Wang ◽  
Li Jing Zou ◽  
Xian Ming Zhang ◽  
Bin Ji
Keyword(s):  
Cutting Force ◽  
Cutting Temperature ◽  
Tool Material ◽  
High Reactivity ◽  
Good Prediction ◽  
Workpiece Material ◽  
Element Analysis ◽  
Good Prediction Accuracy ◽  
Experimental Cutting ◽  
Cutting Tool Materials

Aero-engine alloys (also as known as superalloys) are known as difficult-to-machine materials, especially at higher cutting speeds, due to their several inherent properties such as low thermal conductivity and their high reactivity with cutting tool materials. In this paper a finite element analysis (FEA) of machining for Incoloy907 is presented. In particular, the thermodynamical constitutitve equation (T-C-E) in FEA is applied for both workpiece material and tool material. Cutting temperature and cutting force are predicted. The comparison between the predicted and experimental cutting temperature and cutting force are presented and discussed. The results indicated that a good prediction accuracy of both principal cutting temperature and cutting force can be achieved by the method of FEA with thermodynamical constitutitve equation. Keywords: Incoloy907,Simulation, Thermodynamical constitutitve equation

Finite Element Prediction of Grind-Hardening Layer Thickness

2009 ◽  
Vol 416 ◽  
pp. 253-258 ◽  
Author(s):  
Gui Cheng Wang ◽  
Zhong Feng Pan ◽  
Jin Yu Zhang ◽  
Chong Lue Hua ◽  
Ju Dong Liu
Keyword(s):  
Finite Element ◽  
Linear Regression Analysis ◽  
Multiple Linear Regression Analysis ◽  
Grinding Force ◽  
Heat Distribution ◽  
The Finite Element Method ◽  
Cutting Depth ◽  
Hardening Process ◽  
Grind Hardening ◽  
Finite Element Prediction

According to the grind-hardening test and using the multiple linear regression analysis, the empirical formula of the tangential grinding force is established in this paper. Combined with the heat distribution coefficient formula of Rowe and Pettit, the thickness of the grind-hardening layer is predicted by using the finite element method under different grinding parameters. It draws the influence law of the grinding speed, cutting depth and feed rate to the thickness of the grind-hardening layer. It provided the basis to the drawing up, the application and the optimization of the grind-hardening process.

The effects of circular sawblade diamond segment characteristics on marble processing performance

2009 ◽  
Vol 224 (8) ◽  
pp. 1559-1565 ◽  
Author(s):  
I S Buyuksagis
Keyword(s):  
Cutting Force ◽  
Axial Force ◽  
Linear Regression Analysis ◽  
Multiple Linear Regression Analysis ◽  
Performance Criteria ◽  
Machining Parameters ◽  
Rock Types ◽  
Force Ratio ◽  
The Matrix ◽  
Matrix Hardness

Utilizing a fully instrumented block-cutter, an experimental study was carried out to investigate the effects of diamond/metal matrix properties on the sawing performance of segmented circular sawblades. Six commercially available sawblades differing in segment compositions were used in the sawing experiments of Afyon Tiger Skin Marble. Bond compositions of the tested sawblades were determined by carrying out energy dispersive X-ray spectrometer analysis. The sawing tests were performed in the down-cutting mode. The sawing performances of the sawblades were evaluated in terms of cutting specific energy (SE), cutting force, axial force, and force ratio (ratio of tangential to normal force). The worn surfaces of the diamond segments were examined by scanning electron microscope micrographs. Upon evaluation of the experimental data, it was concluded that the determined performance criteria from laboratory sawing tests can aid manufacturers in the design of appropriate sawblades for specific rock types. Valid for the employed machining parameters, tested sawblade types, and workpiece properties, the results of a multiple linear regression analysis have indicated that the Sn percentage of the segment matrix, the diamond concentration, and the matrix hardness are the common dominant variables that affect cutting SE, axial force, and cutting force.

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