Cutting Forces when High-Speed Milling of SiCP/Al Composites

2011 ◽  
Vol 308-310 ◽  
pp. 871-876 ◽  
Author(s):  
Ying Fei Ge ◽  
Jiu Hua Xu ◽  
Yu Can Fu
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Radial Direction ◽  
Reinforcement Particle ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
High Speed Milling ◽  
Radial Depth ◽  
Pcd Tools

High speed milling tests were performed on the SiCp/2009Al composites to investigate the cutting forces by using PCD tools in the speed range of 600-1200m/min. The results showed that the peak value of the cutting force Fy (in the tool radial direction) was in the range of 700-1450N under the present cutting condition. The maximum amplitude of cutting force vibration in the tool radial direction can reach 700N. Cutting forces increased with increasing feed rate or radial depth of cut and decreased with increasing cutting speed. Negative rake angle and relatively large tool nose radius were recommended as far as cutting forces was concerned. Materials with higher volume fraction or smaller reinforcement particle size had the bigger cutting forces. T6 heat treatment can increase the cutting forces significantly but the using of coolant can decrease the cutting forces evidently.

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%.

Cutting Performance of Diamond Coated, TiAlN Coated and Carbide Cutting Tools in High Speed Milling Graphite

2014 ◽  
Vol 800-801 ◽  
pp. 451-459
Author(s):  
Yu Hai Zhou ◽  
Cheng Yong Wang ◽  
Qi Ming Wang
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Orthogonal Experiment ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Performance ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

This paper focusing on cutting performance high speed milling Electrical Discharging Machining (EDM) graphite with diamond coated、Carbide (WC) and TiAlN coated cutting Tools. tools wear, cutting force and machined surface had been researched. Experiment study including cutting speed, feed rate per tooth, radial depth of cut, axial depth of cut, and material of tools factors effects on the cutting forces. Cutting parameters are optimized based on the orthogonal experiment. Experiment in high speed milling with diamond coated tools all comparison with TiAlN coated and Carbide (WC) tools. On the surface quality, cutting forces and tool wear influence graphite cutting tool materials research, process parameters, tool design and optimization of processing parameters to provide supportive data. The minimum cutting force as the goal, through the orthogonal experiment for the optimization of cutting parameters obtained for the high speed milling graphite with diamond-coated tool: cutting force 360m/min,feed per tooth 0.15mm/z, radial depth of cut 0.9mm, axial depth of 9mm.

Cutting Forces and Vibration of Pockets Corner by High Speed Milling

2009 ◽  
Vol 69-70 ◽  
pp. 59-63 ◽  
Author(s):  
Cheng Yong Wang ◽  
De Weng Tang ◽  
Zhe Qin ◽  
Z.G. Chen ◽  
Ying Ning Hu ◽  
...  
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Sudden Change ◽  
Poor Quality ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Cutting Direction ◽  
Cutting Speeds

When the pocket in die and mould is machined by high speed milling (HSM), the cutting forces increase and vibration fluctuates at the pocket corner because of the sudden change of cutting direction in general. It will cause serious wear and possible breakage of cutting tool, and poor quality of parts. By means of experiments, the cutting forces and vibration at the pocket corner with different HSM conditions are measured. The results show that the sharper pocket corner, higher cutting speeds, larger feed rate per tooth and radial depth of cut, will result in increasing of cutting forces and vibration amplitude. Thus, it will lead to be unstable during the process of high speed milling pocket corner.

Cutting Temperature Investigation when High-Speed Milling of SiCP/Al Composites

2011 ◽  
Vol 697-698 ◽  
pp. 198-203
Author(s):  
Ying Fei Ge ◽  
Jiu Hua Xu ◽  
Yu Can Fu
Keyword(s):  
High Speed ◽  
Volume Fraction ◽  
Influence Factors ◽  
Cutting Temperature ◽  
Depth Of Cut ◽  
Minor Effect ◽  
High Speed Milling ◽  
Tool Materials ◽  
Radial Depth ◽  
Pcd Tools

High-speed milling tests were performed on SiCp/2009Al composites in the speed range of 600-1200m/min using PCD tools to investigate the cutting temperatures and the influence factors. The results showed that the cutting temperature could reach 580°C under the given cutting conditions. Graphitization took place on the PCD tools under the high cutting temperature coupled with the effects of abrasive wear of SiC particles and catalysis of copper in the 2009 aluminum matrix. Cutting parameters, tool materials, workpiece materials and tool wear condition had significant effect on the high speed milling temperature while tool geometries had the minor effect. Among these influence factors, cutting speed was the most significant factor. Reinforcement volume fraction was the less significant factor and followed by radial depth of cut, feed rate and tool materials.

Study on Cutting Forces of Mg-6Nd-4Gd-3Y Magnesium Alloy in High-Speed Milling

2011 ◽  
Vol 338 ◽  
pp. 709-713
Author(s):  
Zhen Hua Wang ◽  
Jun Tang Yuan
Keyword(s):  
Magnesium Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Polynomial Regression ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Partial Least Square ◽  
Depth Of Cut ◽  
High Speed Milling

In this paper, 24full factorial design and homogeneous design were applied to the high-speed milling experiments for Mg-6Nd-4Gd-3Y magnesium alloy. According to the experimental results of cutting force, the effect of cutting parameters (cutting speed, feed per tooth, depth of cut, and width of cut) on cutting force was discussed, and the nonlinear polynomial regression models of cutting forces based on the cutting parameters were presented by the partial least-square regression.

Influence on Cutting Forces and Vibration in High Speed Machining Pocket Corner

2011 ◽  
Vol 189-193 ◽  
pp. 3084-3088
Author(s):  
De Wen Tang ◽  
Ru Shu Peng ◽  
Rui Lan Zhao
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Sudden Change ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Poor Quality ◽  
Depth Of Cut ◽  
Processing Efficiency ◽  
Radial Depth

High speed milling hardened mould steel (above HRC50) at pocket corner generates the cutting forces increase and vibration gets fiercely because of the sudden change of cutting direction. It will cause serious wear and possible breakage of cutting tool, and poor quality of parts. Hence, the need to select reasonable cutting parameters and adopt appropriate cutting strategies will help them to achieve their goal. In this paper, the effects cutting parameters including cutting speed, pocket corner angle, feed rate per tooth and radial depth of cut on cutting force and vibration are studied. The results show that sharper pocket corner results in the increase of cutting force and makes vibration strong. Cutting force increase with the increase of cutting speeding, feed per tooth and radial depth of cut. The optimum of cutting speed leads to the decrease of vibration. It is proposed that cutting parameters should be optimized to improve tool life and processing efficiency.

Experimental Study on Cutting Force of Pocket Corner in HSM

2010 ◽  
Vol 29-32 ◽  
pp. 215-219
Author(s):  
Zhen Yu Zhao ◽  
Ming Jun Liu ◽  
Bai Liu
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Machining Accuracy ◽  
Processing Efficiency ◽  
High Speed Milling ◽  
Radial Depth ◽  
The Impact

Pocket corner in the high-speed milling (HSM) often occur under-cut, over-cut, vibration and other phenomena. This not only reduces tool life, seriously affected the work-piece machining accuracy and processing efficiency. In the paper, the impact of cutting speed on cutting forces is studied in the pocket corner based on the high-speed milling experiments. The results show that cutting force increased slightly with the increase in cutting speed, and that cutting force no significant change with the increase in radial depth of cut.

Machining Evaluation of High-Speed Milling for Thin-Wall Machining of Al7075-T651

2014 ◽  
Vol 541-542 ◽  
pp. 785-791 ◽  
Author(s):  
Joon Young Koo ◽  
Pyeong Ho Kim ◽  
Moon Ho Cho ◽  
Hyuk Kim ◽  
Jeong Kyu Oh ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Cutting Forces ◽  
High Speed ◽  
Surface Condition ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Thin Wall ◽  
Machined Surface ◽  
High Speed Milling

This paper presents finite element method (FEM) and experimental analysis on high-speed milling for thin-wall machining of Al7075-T651. Changes in cutting forces, temperature, and chip morphology according to cutting conditions are analyzed using FEM. Results of machining experiments are analyzed in terms of cutting forces and surface integrity such as surface roughness and surface condition. Variables of cutting conditions are feed per tooth, spindle speed, and axial depth of cut. Cutting conditions to improve surface integrity were investigated by analysis on cutting forces and surface roughness, and machined surface condition.

Tool Wear Characteristics in High Speed Milling of Ti-6Al-4V Alloy with Nitrogen Gas Medium

2006 ◽  
Vol 315-316 ◽  
pp. 588-592 ◽  
Author(s):  
Wei Zhao ◽  
Ning He ◽  
Liang Li ◽  
Z.L. Man
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Oil Mist ◽  
Electron Microscopes ◽  
Scanning Electron Microscopes

High speed milling experiments using nitrogen-oil-mist as cutting medium were undertaken to investigate the characteristics of tool wear for Ti-6Al-4V Alloy, a kind of important and commonly used titanium alloy in the aerospace and automobile industries. Uncoated carbide tools have been applied in the experiments. The cutting speed was 300 m/min. The axial depth of cut and the radial depth of cut were kept constant at 5.0 mm and 1.0 mm, respectively. The feed per tooth was 0.1 mm/z. Optical and scanning electron microscopes have been utilized to determine the wear mechanisms of the cutting tools, and energy spectrum analysis has been carried out to measure the elements distribution at the worn areas. Meanwhile, comparisons were made to discuss the influence of different cutting media such as nitrogen-oil-mist and air-oil–mist upon the tool wear. The results of this investigation indicate that the tool life in nitrogen-oil-mist is significantly longer than that in air-oil-mist, and nitrogen-oil-mist is more suitable for high speed milling of Ti-6Al-4V alloy than air-oil-mist.

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.

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