Investigation into the rotary ultrasonic face milling of K9 glass with mechanism study of material removal

2012 ◽  
Vol 25 (4) ◽  
pp. 248 ◽  
Author(s):  
Chenglong Zhang ◽  
Pingfa Feng ◽  
Jianfu Zhang ◽  
Zhijun Wu ◽  
Dingwen Yu
Keyword(s):  
Material Removal ◽  
Face Milling ◽  
Mechanism Study ◽  
K9 Glass

Theoretical and Experimental Research on the Features of Cutting Force in Rotary Ultrasonic Face Milling of K9 Glass

2012 ◽  
Vol 157-158 ◽  
pp. 1674-1679 ◽  
Author(s):  
Cheng Long Zhang ◽  
Ping Fa Feng ◽  
Jian Fu Zhang ◽  
Zhi Jun Wu ◽  
Ding Wen Yu
Keyword(s):  
Cutting Force ◽  
Material Removal ◽  
Diamond Particle ◽  
Process Variable ◽  
Face Milling ◽  
Process Conditions ◽  
Cutting Depth ◽  
Surface Machining ◽  
Cutting Length ◽  
K9 Glass

This study introduces rotary ultrasonic face milling (RUFM) process into flat surface machining of K9 glass. The effective cutting velocity, and cutting length of single diamond particle were presented in RUFM. The model of material removal for RUFM was developed through examining indentation fracture mechanics theory and material removal characteristics of brittle materials, and analyzing kinematics properties of diamond grits in RUFM. With a view of comparative researches, the cutting force of RUFM and diamond milling of K9 glass are compared. The experimental results tell that the relationship between the cutting depth (dc) and the ultrasonic amplitude (A) of the cutter has remarkable effects on cutting force, which was also discussed in the kinematic characteristics analysis section. The results also show that RUFM process can significantly reduce cutting force and the effects of process variable changes on cutting force in RUFM are weaker as dc is smaller than A. However, the reduction trends of the cutting forces in RUFM are very small and even increased in some process conditions, as dc is larger than A. It suggests that the cutting depth should be smaller than the ultrasonic amplitude of the cutter with RUFM process to obtain better processing performance.

Productivity Considerations in Face Milling

2019 ◽  
Vol 952 ◽  
pp. 66-73
Author(s):  
János Kundrák ◽  
Viktor Molnár ◽  
István Deszpoth ◽  
Tamás Makkai
Keyword(s):  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Face Milling ◽  
Manufacturing Companies ◽  
Performance Limits ◽  
Machining Time ◽  
High Productivity ◽  
Manufacturing Time

The kinematic versions and applied tools of milling allow for the machining of several surfaces and surface combinations, making it a versatile and widely applied procedure. Face milling for cutting is used for the high productivity manufacturing of prismatic components. Naturally, the enhancement of productivity is a primary goal for manufacturing companies; this study analyzes the efficiency of material removal, which directly influences the time parameters characterizing production performed by face milling. The focus of the paper is to identify the selection of technological data (feed, feed rate, cutting speed, diameter of milling head) that can reduce the machining time or increase the values of material removal rate. Cutting experiments were carried out for machining prismatic components from AlSi9Cu3(Fe) aluminum alloy by diamond tools. It was found that within the performance limits of the manufacturing system it is possible to save a significant amount of manufacturing time while retaining the specified geometric accuracy and surface quality of the component.

scholarly journals Multi-Objective Process Parameter Optimization for Surface Roughness and Material Removal Rate in Face Milling of Al 6061 T6 Alloy

2019 ◽  
Vol 9 (2) ◽  
pp. 137-142
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Face Milling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Al 6061

This study uses Taguchi methodology and Gray Relational Analysis approach to explore the optimization of face milling process parameters for Al 6061 T6 alloy.Surface Roughness (Ra), Material Removal Rate (MRR) has been identified as the objective of performance and productivity.The tests were performed by selecting cutting speed (mm / min), feed rate (mm / rev) and cutting depth (mm) at three settings on the basis of Taguchi's L9 orthogonal series.The grey relational approach was being used to establish a multiobjective relationship between both the parameters of machining and the characteristics of results. To find the optimum values of parameters in the milling operation, the response list and plots are used and found to be Vc2-f1-d3. To order to justify the optimum results, the confirmation tests are performed.The machining process parameters for milling were thus optimized in this research to achieve the combined goals such as low surface roughness and high material removal rate on Aluminum 6061 t6.It was concluded that depth of cut is the most influencing parameter followed by feed rate and cutting velocity.

A model for prediction of subsurface damage in rotary ultrasonic face milling of optical K9 glass

2015 ◽  
Vol 83 (1-4) ◽  
pp. 347-355 ◽  
Author(s):  
Jianjian Wang ◽  
Chenglong Zhang ◽  
Pingfa Feng ◽  
Jianfu Zhang
Keyword(s):  
Face Milling ◽  
Subsurface Damage ◽  
K9 Glass

scholarly journals Investigations of surface quality and energy consumption associated with costs and material removal rate during face milling of AISI 1045 steel

2020 ◽  
Vol 107 (7-8) ◽  
pp. 3511-3525 ◽  
Author(s):  
Danil Yu. Pimenov ◽  
Adel Taha Abbas ◽  
Munish Kumar Gupta ◽  
Ivan N. Erdakov ◽  
Mahmoud Sayed Soliman ◽  
...  
Keyword(s):  
Energy Consumption ◽  
Surface Quality ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Face Milling ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Development of Nanomachining Mechanism Based on Molecular Dynamics Simulation

2015 ◽  
Vol 667 ◽  
pp. 41-46
Author(s):  
Peng Yue Zhao ◽  
Yong Bo Guo ◽  
Guo Kun Qu
Keyword(s):  
Molecular Dynamics ◽  
Material Removal ◽  
Polycrystalline Material ◽  
Molecular Dynamics Method ◽  
Dynamics Simulation ◽  
Mechanism Study ◽  
Nanoscale Material ◽  
Plastic Materials ◽  
Nanometric Machining ◽  
Dynamics Method

Nanomachining technology has broad application prospects and molecular dynamics method is an important research tools for studying nanoscale material removal mechanism. This paper is focused on the analysis of basic principle of molecular dynamics method and the progress of nanomachining model. The nanomachining mechanism of single crystalline brittle materials and plastic materials are investigated completely, micro-nanomachining mechanism of polycrystalline material is also summarized, The challenges and future development of the nanometric machining mechanism study are also discussed.

scholarly journals Optimization of Face Milling Parameters Considering Wear and Tool Life of Cutters to Improve the Quality, Cost and Power Consumption

2018 ◽  
Author(s):  
Danil Y. Pimenov ◽  
Munish K. Gupta ◽  
Ivan N. Erdakov ◽  
Adel T. Abbas ◽  
Mahmoud S. Soliman ◽  
...  
Keyword(s):  
Power Consumption ◽  
Tool Life ◽  
Material Removal ◽  
Cutting Speed ◽  
Face Milling ◽  
Manufacturing Industries ◽  
Cutting Length ◽  
The Cost ◽  
Sliding Distance ◽  
Tooth Cutting

Face milling is a well known commercial process highly used in heavy industries that consumes high amount of power. Besides power issue, modern manufacturing industries are aiming for per part cost reduction keeping the product quality unimpaired. Unexpectedly if the part is rejected in any stage of manufacturing, the cost of manufacturing dramatically increases. Major cause of part rejection is excessive tool wear that imparts poor surface profile or catastrophic tool failure that causes adherence of broken tool debris onto machined surface. Furthermore, the tool wear is associated with sliding distance (frictional distance) and the tool life quantifies the cost of tools. As such, from the perspective of manufacturing industries it is imperative to optimize the surface quality parameter, cost of part, power consumption, and material removal – this is exactly what is accomplished here. By this work, it is possible to conserve power consumption, produce parts with lower cost, manufacture with uncompromising surface quality and enhanced material removal rate. Moreover, as intermediate factors of interest, the influences of sliding distance, tool life and tool flank wear on the overall machining performance are evaluated. The multi-objective optimization by Grey Relational Analysis (GRA) revealed that for improved product performance and fast manufacturing (case 1) optimum results are: feed per tooth fz = 0.25 mm/tooth, cutting speed vc = 392.6 m/min and cutting length l = 0.5 mm; for resource conservation (case 2) the optimum results are: feed per tooth fz = 0.125 mm/tooth, cutting speed vc = 392.6 m/min, cutting length l = 0.5 mm.

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