scholarly journals INVESTIGATION OF THE EFFECT OF DEPTH OF CUT AND CUTTING SPEED ON CUTTING FORCES DURING FACE MILLING OF STEEL WITH A RECTANGULAR CUTTING INSERT

2019 ◽  
Vol 0 (90) ◽  
pp. 3-9
Author(s):  
Nikolaos E. Karkalos ◽  
Angelos P. Markopoulos ◽  
Tamás Makkai ◽  
János Kundrák
Keyword(s):  
Cutting Forces ◽  
Cutting Speed ◽  
Face Milling ◽  
Depth Of Cut ◽  
Cutting Insert

scholarly journals INFLUENCE OF DEPTH OF CUT AND CUTTING SPEED ON CUTTING FORCES IN FACE MILLING UNDER CONSTANT CHIP CROSS-SECTION CONDITIONS

2019 ◽  
Vol 0 (90) ◽  
pp. 10-16 ◽  
Author(s):  
Nikolaos E. Karkalos ◽  
Angelos P. Markopoulos ◽  
Tamás Makkai ◽  
János Kundrák
Keyword(s):  
Cross Section ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Face Milling ◽  
Depth Of Cut

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%.

Wear Behavior of Carbide Inserts in Face Milling TA19 Alloy

2012 ◽  
Vol 426 ◽  
pp. 339-343 ◽  
Author(s):  
Qiu Lin Niu ◽  
X.J. Cai ◽  
Zhi Qiang Liu ◽  
Ming Chen ◽  
Qing Long An
Keyword(s):  
Titanium Alloy ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Aircraft Engine ◽  
Face Milling ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Crater Wear ◽  
Stable Conditions ◽  
Carbide Inserts

As a typical high strength material, titanium alloy Ti-6Al-2Sn-4Zr- 2Mo-0.1Si (TA19) is used to manufacturing the compressor power-brake of aircraft engine and the aircraft skin. All the machining experiments were carried out on a CNC-milling center under the stable conditions of cutting speed, feed rate, and depth of cut. The performance and wear mechanisms of coated- and uncoated carbide tools have been investigated in this paper to evaluate the machinability of TA19 in face milling. The three tools used were PVD-TiN+TiAlN, CVD-TiN+Al2O3+TiCN and uncoated carbide inserts. The results indicated that PVD coating had the best performance than other tool materials in milling titanium alloy TA19, and the cutting force and the wear value were the smallest than that for CVD-coated and uncoated tools. The failure types of PVD-, CVD- and uncoated inserts were the crater wear and micro tipping; the crater wear and tipping; tipping. Abrasive wear and adherent wear were the predominant mechanism of PVD-TiN+TiAlN carbide insert in face milling TA19 alloy. For CVD- and uncoated carbide, adherent wear was predominant.

scholarly journals Nanofluid-based Minimum Quantity Lubrication (MQL) Face Milling of Inconel 625

2019 ◽  
Vol 16 (3) ◽  
pp. 6874-6888
Author(s):  
P. Singh ◽  
J. S. Dureja ◽  
H. Singh ◽  
M. S. Bhatti
Keyword(s):  
Negative Impact ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Face Milling ◽  
Cutting Fluid ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Base Oil ◽  
Minimum Quantity ◽  
Milling Parameters

Machining with minimum quantity lubrication (MQL) has gained widespread attention to boost machining performance of difficult to machine materials such as Ni-Cr alloys, especially to reduce the negative impact of conventional flooded machining on environment and machine operator health. The present study is aimed to evaluate MQL face milling performance of Inconel 625 using nano cutting fluid based on vegetable oil mixed with multi-walled carbon nanotubes (MWCNT). Experiments were designed with 2-level factorial design methodology. ANOVA test and desirability optimisation method were employed to arrive at optimised milling parameters to achieve minimum tool wear and machined surface quality. Experiments were performed under nanoparticles based minimum quantity lubrication (NMQL) conditions using different weight concentrations of MWCNT in base oil: 0.50, 0.75, 1, 1.25 and 1.5 wt. %; and pure MQL environment (without nanoparticles). The optimal MQL milling parameters found are cutting speed: 47 m/min, table feed rate: 0.05 mm/tooth and depth of cut: 0.20 mm. The results revealed improvement in the surface finish (Ra) by 17.33% and reduction in tool flank wear (VB) by 11.48 % under NMQL face milling of Inconel 625 with 1% weight concentration of MWCNT in base oil compared to pure MQL machining conditions.

Thermal hardening and calculation of the mathematical model of face milling of parts made of steel 95X18-Sh to improve the quality of the surface layer

2021 ◽  
pp. 200-206
Author(s):  
I.N. Sedinin ◽  
V.F. Makarov
Keyword(s):  
Mathematical Model ◽  
Cutting Speed ◽  
Physical And Mechanical Properties ◽  
Face Milling ◽  
Experiment Planning ◽  
Depth Of Cut ◽  
Machined Surface ◽  
The Mathematical Model ◽  
Full Factorial

It is considered the complex of operations of the technological process for the heat treatment of steel 95X18-Sh, as a result of which the material of the samples increases the hardness to 59...61 HRC, and also improves the physical and mechanical properties. A full-scale full factorial experiment of face milling of samples was carried out using the method of mathematical planning. In the experiments, a high-precision machine and a carbide cutting tool were used. To calculate the values of the roughness function, the following are taken as independent variables: cutting speed, feed per tooth and depth of cut. In order to determine the coefficients of the linear equation, a central compositional orthogonal plan of the second order for three factors was used. A matrix of levels of variation of independent variable factors and a matrix of experiment planning were compiled. A regression analysis of the obtained experimental statistical data was carried out using the Microsoft Excel, Statistica and Wolfram Alpha programs. As a result of the calculations, a mathematical model of the roughness of the machined surface and optimal cutting conditions were determined.

Predictive Modeling and Optimization of Cutting Forces Through RSM and Taguchi Techniques in the Turning of ASTM B574 (Hastelloy C-22)

2018 ◽  
pp. 398-417
Author(s):  
İsmail Kırbaş ◽  
Musa Peker ◽  
Gültekin Basmacı ◽  
Mustafa Ay
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Orthogonal Experimental Design ◽  
Depth Of Cut ◽  
Effective Parameters ◽  
Factors Affecting ◽  
The Impact

In this chapter, the impact of cutting parameters (depth of cut, cutting speed, feed, flow, rake angle, lead angle) on cutting forces in the turning process with regard to ASTM B574 (Hastelloy C-22) material has been investigated. Variance analysis has been applied in order to determine the factors affecting the cutting forces. The optimization of the parameters affecting the surface roughness has been obtained using response surface methodology (RSM) based on the Taguchi orthogonal experimental design. The accuracy of the developed models required for the estimation of the force values (Fx, Fy, Fz) is quite successful. In this study, where the R2 value has been used as the criterion/measure, accuracy values of 93.35%, 95.03%, and 95.09% have been achieved for Fx, Fy, and Fz, respectively. As a result of the ANOVA analysis, the most effective parameters for Fx at a 95% confidence interval are depth of cut, feed rate, flow, and rake angle. The most effective parameter for Fy is depth of cut, while the most effective parameters for Fz are depth of cut, feed rate, and flow, respectively.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

The machinability of Al/B4C composites produced by hot pressing based on reinforcing the element ratio

2016 ◽  
Vol 23 (6) ◽  
pp. 743-750 ◽  
Author(s):  
Ergün Ekici ◽  
Mahmut Gülesin
Keyword(s):  
Surface Roughness ◽  
Wear Mechanism ◽  
Cutting Forces ◽  
Hot Pressing ◽  
Matrix Material ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Reinforcement Ratio ◽  
Depth Of Cut ◽  
Crater Wear

AbstractIn this study, the effects of the particle reinforcement ratio on cutting forces and surface roughness were investigated when milling particle-reinforced metal matrix composite (MMCp) produced by hot pressing with different cutting tools. Alumix 123 alloy as the matrix material and B4C particles with an average size of 27 μm and 5%, 10% and 15% ratio as reinforcing elements were used for the manufacture of composite materials. The experiments were carried out in dry cutting conditions with four different cutting speeds, constant feed rate and depth of cut. Changes depending on the increased reinforcement ratio in cutting forces and surface roughness values were investigated; the effects of 10% B4C reinforced composite on tool wear were also examined. It was observed that cutting forces increased with the increase in cutting speed and particle ratio with carbide cutting tools, and it was seen that the cutting forces on the cutting tools decreased when cutting speed decreased and the cutting forces increased as the reinforcement ratios increased. In addition, with increasing the cutting speed, the surface roughness of the machined surfaces of composite samples increased with the carbide tools, while the cubic boron nitride (CBN) tools have the opposite effect. While it was seen that flank and crater wear occurred on the cemented carbide cutting tools, abrasive, adhesive and other wear mechanism tools in addition to the main wear mechanism, no remarkable flank and crater wear occurred on CBN cutting tools.

Assessment of the Cutting Tooling Effect on Turning Chatter

2013 ◽  
Vol 433-435 ◽  
pp. 2101-2106
Author(s):  
Joon Hwang ◽  
Ey Hyoun Jeong ◽  
Eui Sik Chung ◽  
Steven Y. Liang
Keyword(s):  
Cutting Forces ◽  
Cutting Speed ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Nonlinear Phenomenon ◽  
Chatter Vibration ◽  
Machining Performance ◽  
Dynamic Component ◽  
Excited Vibration ◽  
Overhang Length

Machining performance is often limited by chatter vibration at the tool-workpiece interface. Chatter is a type of machining self-excited vibration which originates from the variation in cutting forces and the flexibility of the machine tool structure. Machining chatter is an inherently nonlinear phenomenon that is affected by many parameters such as cutting conditions, tool geometry, cutting speed, feed rate, depth of cut, overhang length of tool, clamping condition of workpiece. This study presents experimental approach for investigation of effects of various cutting tool geometry on the onset of chatter. In turning process, measured cutting force signal and triaxial accelerometer signal was used to know the characteristics of chatter vibration. The static and dynamic component of cutting forces reflect onset of chatter vibration. Proper selection of tooling is an important parameter in terms of chatter elimination in machining.

Cutting Model in Machining of Al/SiCp Metal Matrix Composite

2011 ◽  
Vol 410 ◽  
pp. 291-297
Author(s):  
Sayed Mohamad Nikouei ◽  
R. Yousefi ◽  
Mohammad Ali Kouchakzadeh ◽  
M.A. Kadivar
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Shear Plane ◽  
Good Method ◽  
Depth Of Cut ◽  
Machining Forces ◽  
Experimental Cutting ◽  
Cutting Model

Prediction of shear plane angle is a way for prediction of the mechanism of chip formation, machining forces and so on. In this study, Merchant and Lee-Shaffer theories are used for prediction of shear plane angles and cutting forces in machining of Al/SiCpMMC with 20% of SiC as reinforcement particles. The experimental cutting forces are compared with the calculated cutting force based on shear plane angles extracted from Merchant and Lee-Shaffer theories. The variation of these cutting forces with cutting speed, feed rate and depth of cut has been discussed. The results showed that Merchant theory may be used as a good method for prediction of chip formation in machining of Al/SiCpMMC.

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