Analysis on the Effects of Tool Rake Angle and Helix Angle of a Flat End-mill in the Milling of Ti-alloy

Purpose The purpose of this paper is to find out the optimal level as well as the influence of end mill cutter geometrical and machining parameters while machining metal matrix composite. End milling is carried out on Al 356/SiC metal matrix composites (MMC) using high-speed steel (HSS) end mill cutter. The optimum level of input parameters such as helix angle, nose radius, rake angle, cutting speed, feed rate and depth of cut are calculated for minimum temperature rise. Design/methodology/approach L27 Taguchi orthogonal design, signal-to-noise (S/N) ratio, are applied for conducting experiments, and to find the optimal level of input parameters for minimum temperature rise, respectively. Analysis of variance (ANOVA) is used to analyze the significance of input parameters on temperature rise. Findings It is found that the optimal combination of helix angle 400, nose radius 0.8 mm, rake angle 80, cutting speed 30 m/min, feed rate 0.04 mm/rev and depth of cut 0.5 mm have generated minimum temperature rise. From ANOVA analysis, it is found that rake angle influence is more on output performance followed by cutting speed and nose radius compared with other machining and geometrical parameters. Originality/value The influence of geometrical parameters such as helix angle, nose radius and rake angle of end mill cutter on temperature rise while machining MMC has not been explored previously.

Download Full-text

Surgical Drilling: Design and Performance of an Improved Drill

Journal of Biomechanical Engineering ◽

10.1115/1.3138356 ◽

1982 ◽

Vol 104 (3) ◽

pp. 245-252 ◽

Cited By ~ 79

Author(s):

S. Saha ◽

S. Pal ◽

J. A. Albright

Keyword(s):

Compact Bone ◽

Helix Angle ◽

Rake Angle ◽

Peak Temperature ◽

Published Data ◽

Drill Bit ◽

Effective Removal ◽

Split Point ◽

And Performance ◽

Twist Drills

The majority of twist drills used in orthopaedics are very similar to chisel pointed metal drilling bits. Modifications usually observed are reduction of the point angle to 90 deg and sometimes grinding of the entire cutting lip at 0 deg rake angle, which appeared to have been made arbitrarily without any advantage. We have attempted to design a surgical drill bit with the objective of minimization of the drilling thrust and temperature and effective removal of bone chips. Our results showed that the presence of the chisel edge was mainly responsible for increasing the thrust force and the temperature developed. The effects of a constant feed rate and thrust on the peak temperature were also examined. The combined effect of the helix and the point angles on the rake angle which in turn determines the cutting efficiency was analyzed for various types of surgical bits. Based on our results and previously published data from the literature an optimized drill bit was designed with a split point, a point angle of 118 deg, a parabolic flute, and a helix angle of 36 deg and its performance was compared with other existing surgical drill bits. For drilling in compact bone, the new design decreased the thrust load by 45 percent and the peak temperature rise by 41 percent. Simlar improvements were also recorded for drilling bone cement. The time of drilling a bone cortex was also significantly reduced and “walking” on the curved bone surface was eliminated and dimensional tolerance on hole sizes was improved. The new design is likely to reduce the time of surgery and also minimize the tissue damage.

Download Full-text

Five-Axis CNC Tool Grinding: Part I—Rake Face Grinding

ASME 2011 International Manufacturing Science and Engineering Conference, Volume 1 ◽

10.1115/msec2011-50014 ◽

2011 ◽

Cited By ~ 2

Author(s):

Mahmoud M. Rababah ◽

Zezhong C. Chen

Keyword(s):

Rake Angle ◽

Grinding Process ◽

Rake Face ◽

End Mill ◽

Grinding Wheels ◽

Robust Algorithm ◽

Geometric Representations ◽

Five Axis ◽

Face Grinding ◽

Tool Grinding

Grinding the helical surfaces in end-mill cutters using two-axis CNC machines is well investigated in literature. However, the grinding wheels do not have explicit geometric representations and the produced helical angles differ from the designed values. Moreover, to the best knowledge of the authors, no reliable and robust algorithm exists to grind generic shape cutters with constant normal rake angles. Thus, the first part of this work introduces a five-axis grinding process that keeps the normal rake angle constant along the rake face. The parameters that affect the shape of the tool flutes are also analyzed and studied in this part. These parameters are then optimized in the second part to obtain optimum wheel shapes grinding the tool flutes along optimum paths. Overall, the grinding process proposed grinds the tool flutes with close matching to the designed ones and replaces the complex wheel shapes commonly used by simple prismatic ones.

Download Full-text

The influence of end mill helix angle on high performance milling process

Journal of Mechanical Science and Technology ◽

10.1007/s12206-020-0131-6 ◽

2020 ◽

Vol 34 (2) ◽

pp. 817-827 ◽

Cited By ~ 2

Author(s):

Marcin Plodzien ◽

Jan Burek ◽

Lukasz Zylka ◽

Pawel Sulkowicz

Keyword(s):

High Performance ◽

Helix Angle ◽

Milling Process ◽

End Mill

Download Full-text

Influence of Cutting Parameters and Tool Geometric Angles on TC4 Titanium Alloy Chip Shape

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.490-495.3912 ◽

2012 ◽

Vol 490-495 ◽

pp. 3912-3915 ◽

Cited By ~ 2

Author(s):

Wei Hua Wu ◽

Wen Min Chen ◽

Xue Hui Wang ◽

Can Zhao

Keyword(s):

Titanium Alloy ◽

Tool Life ◽

Cutting Parameters ◽

Helix Angle ◽

Rake Angle ◽

Serrated Chip ◽

Tc4 Titanium Alloy ◽

Chip Shape ◽

Radial Depth ◽

Geometric Angles

To select reasonable cutting parameters, improve the processing surface quality, and extend the tool life, this paper uses four solid carbide end milling tools to process TC4 titanium alloy, and analyses the influence of the difference cutting parameters and the geometric angles to chip shape. The experiment results indicate that the degree of serrated chip shape is increased by increasing the feed rate under the condition of certain spindle speed. But the degree of serrated chip shape may be decreased by the adoption of small axial and radial depth, or bigger rake angle and smaller helix angle. Select larger rake angle, cutting edge is sharp, the metal deformation of cutting layer is small, which can reduce the friction force when chip flowing through the tool rake face, so that the cutting force and cutting temperature decreases accordingly.The greater the helix angle is, the worse the chip removal conditions is, and the degree of serrated chip becomes larger, the blade is more sharp, easily crack, and the tool life decreases. So relatively small helix angle is better. The choice of angles is interrelated with each other, the selection of some angle separately cannot get the desired reasonable value.

Download Full-text

High-Quality End Milling of CFRP – Inclination Milling with High-Helix End Mill –

International Journal of Automation Technology ◽

10.20965/ijat.2016.p0372 ◽

2016 ◽

Vol 10 (3) ◽

pp. 372-380 ◽

Cited By ~ 1

Author(s):

Akira Hosokawa ◽

◽

Naoya Hirose ◽

Takashi Ueda ◽

Tomohiro Koyano ◽

...

Keyword(s):

Tool Wear ◽

Cutting Force ◽

Surface Integrity ◽

Helix Angle ◽

Surface Generation ◽

End Mill ◽

Side Milling ◽

Pull Out ◽

End Mills ◽

Coated Carbide

Side milling tests of CFRP (carbon fiber reinforced plastics) containing thermosetting resin are carried out by TiAlN/AlCrN-coated, H2-free DLC (diamond-like carbon)-coated, and CVD diamond-coated carbide end mills without coolant. Two types of end mills having different helix angles of 30° and 60° are used. The film thickness and surface smoothness are varied for the DLC-coated end mills. The cutting characteristics are evaluated by tool wear and surface integrity (i.e., 3D profiles of the machined surface, generation of fluffing, delamination, and pull-out of the carbon fibers). The cutting force and tool flank temperature are also examined for the two types of CFRP composites and the helix angle of the end mill. “Inclination milling,”in which the end mill is tilted so that the resultant cutting force acts parallel to the work surface, is proposed as a novel technique to be used with a high-helix angle end mill. This unique approach enables the reduction of tool wear and improves the surface integrity of machined CFRP surfaces.

Download Full-text

29pm3-PN-3 Micro cutting of Ni-Ti alloy using small end mill

The Proceedings of the Symposium on Micro-Nano Science and Technology ◽

10.1299/jsmemnm.2015.7._29pm3-pn-_2 ◽

2015 ◽

Vol 2015.7 (0) ◽

pp. _29pm3-PN--_29pm3-PN-

Author(s):

Kazuya Hamaguchi ◽

Atsushi Yamaguchi ◽

Akihiro Hirayama

Keyword(s):

Ti Alloy ◽

End Mill ◽

Micro Cutting

Download Full-text

Effect of Grinding Wheel Diameter Change on Geometrical Parameters of Ball-Nose End Mill

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.97-101.4527 ◽

2010 ◽

Vol 97-101 ◽

pp. 4527-4529 ◽

Cited By ~ 1

Author(s):

Lin He ◽

L.M. Sun ◽

Xian Feng Zhao ◽

Jun Wang

Keyword(s):

Visual Basic ◽

Rake Angle ◽

Simulation System ◽

Grinding Wheel ◽

Geometrical Parameters ◽

Rake Face ◽

End Mill ◽

Visual Basic For Applications ◽

Grinding Simulation ◽

Diameter Change

The grinding simulation system of ball-nose end mill rake face is developed based on the four axis linkage mathematical model using Solidworks and Visual Basic for Applications (VBA). Effects of grinding wheel diameter change due to wear on geometrical parameters of ball-nose end mill, such as ball-nose rake angle, column rake angle and edge strip width are investigated.

Download Full-text