Experimental Study of End Milling Force on Manganese Steel

2013 ◽  
Vol 718-720 ◽  
pp. 239-243
Author(s):  
Girma Seife Abebe ◽  
Ping Liu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Second Order ◽  
Manganese Steel ◽  
Depth Of Cut ◽  
Machining Deformation ◽  
Radial Depth ◽  
Axial Depth

Cutting force is a key factor influencing the machining deformation of weak rigidity work pieces. In order to reduce the machining deformation and improve the process precision and the surface quality, it is necessary to study the factors influencing the cutting force and build the regression model of cutting forces. This paper discusses the development of the first and second order models for predicting the cutting force produced in end-milling operation of modified manganese steel. The first and second order cutting force equations are developed using the response surface methodology (RSM) to study the effect of four input cutting parameters (cutting speed, feed rate, radial depth and axial depth of cut) on cutting force. The separate effect of individual input factors and the interaction between these factors are also investigated in this study. The received second order equation shows, based on the variance analysis, that the most influential input parameter was the feed rate followed by axial depth, and radial depth of cut. It was found that the interaction of feed with axial depth was extremely strong. In addition, the interactions of feed with radial depth; and feed rate with radial depth of cut were observed to be quite significant. The predictive models in this study are believed to produce values of the longitudinal component of the cutting force close to those readings recorded experimentally with a 95% confident interval.

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%.

Experimental Study on the Relationship between Surface Roughness and Cutting Parameters when Face Milling High Strength Steel

2010 ◽  
Vol 139-141 ◽  
pp. 782-787
Author(s):  
Yue Ding ◽  
Wei Liu ◽  
Xi Bin Wang ◽  
Li Jing Xie ◽  
Jun Han
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
High Strength Steel ◽  
Cutting Speed ◽  
High Strength ◽  
Face Milling ◽  
Depth Of Cut ◽  
Radial Depth ◽  
The Relationship ◽  
Axial Depth

In this study, surface roughness generated by face milling of 38CrSi high-strength steel is discussed. Experiments based on 24 factorial design and Box-Behnken design method are conducted to investigate the effects of milling parameters (cutting speed, axial depth of cut and radial depth of cut and feed rate) on surface roughness, and a second-order model of surface roughness is established by using surface response methodology (RSM); Significance tests of the model are carried out by the analysis of variance (ANOVA). The results show that the most important cutting parameter is feed rate, followed by radial depth of cut, cutting speed and axial depth of cut. Moreover, it is verified that the predictive model possesses highly significance by the variance examination at a level of confidence of 99%. And the relationship between surface roughness and the important interaction terms is nonlinear.

scholarly journals PREDICTION OF TANGENTIAL CUTTING FORCE IN END MILLING OF MEDIUM CARBON STEEL BY COUPLING DESIGN OF EXPERIMENT AND RESPONSE SURFACE METHODOLOGY

1970 ◽  
Vol 40 (2) ◽  
pp. 95-103 ◽  
Author(s):  
Md. Anayet Patwari ◽  
A.K.M. Nurul Amin ◽  
Waleed F. Faris
Keyword(s):  
Response Surface Methodology ◽  
Carbon Steel ◽  
Cutting Force ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Medium Carbon Steel ◽  
Depth Of Cut ◽  
Medium Carbon

The present paper discusses the development of the first and second order models for predicting the tangential cutting force produced in end-milling operation of medium carbon steel. The mathematical model for the cutting force prediction has been developed, in terms of cutting parameters cutting speed, feed rate, and axial depth of cut using design of experiments and the response surface methodology (RSM). All the individual cutting parameters affect on cutting forces as well as their interaction are also investigated in this study. The second order equation shows, based on the variance analysis, that the most influential input parameter was the feed rate followed by axial depth of cut and, finally, by the cutting speed. Central composite design was employed in developing the cutting force models in relation to primary cutting parameters. The experimental results indicate that the proposed mathematical models suggested could adequately describe the performance indicators within the limits of the factors that are being investigated. The adequacy of the predictive model was verified using ANOVA at 95% confidence level. This paper presents an approach to predict cutting force model in end milling of medium carbon steel using coated TiN insert under dry conditions and full immersion cutting.Keywords: Tangential Cutting Forces; RSM; coated TiN; model.DOI: 10.3329/jme.v40i2.5350Journal of Mechanical Engineering, Vol. ME 40, No. 2, December 2009 95-103

The Influence of Cutting Parameters on the Cutting Forces when Milling Invar36

2014 ◽  
Vol 988 ◽  
pp. 296-299
Author(s):  
Xing Wei Zheng ◽  
Guo Fu Ying ◽  
Jia Lu ◽  
Ni Hong Yang ◽  
Yan Chen ◽  
...  
Keyword(s):  
Experimental Study ◽  
Cutting Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Regression Equation ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Coated Carbide ◽  
Carbide Insert ◽  
Axial Depth

An experimental study on milling of Invar36 was conducted by using coated carbide insert to characterize the cutting force. The Taugchi's design of experiment was used for experimentation and the cutting force regression equation was established based on the principles of probability statistics and regression analysis. The results showed that the cutting force was significantly affected by the axial depth of cut and the feed per tooth, and with the increase of the axial depth of cut, the cutting force increased very quickly. Compared with the axial depth of cut, radial depth of cut and cutting speed had less influence on the cutting force. The established regression equation was highly reliable.

The Study of Coated Carbide Ball End Milling Tools on Inconel 718 Using Numerical Simulation Analysis to Attain Cutting Force and Temperature Predictive Models at the Cutting Zone

2017 ◽  
Vol 882 ◽  
pp. 28-35 ◽  
Author(s):  
S.E.M. Chien ◽  
M.M. Reddy ◽  
V.C.C. Lee ◽  
D. Sujan
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Cutting Force ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Ball End Milling ◽  
Cutting Zone ◽  
Coated Carbide

The unique properties of Inconel 718 make it a challenging material to machine especially in ball end milling operations due to high cutting force and temperature concentrated at the cutting zone. These essentially lead to accelerated tool wear and failure resulting in high costs and loss of production. In this research, finite element numerical simulation was performed using AdvantEdge to simulate ball end milling using an 8mm TiAlN coated carbide tool. Response Surface Methodology (RSM) is applied by using a 3 level 3 factorial Box-Behnken design of experiment with different combinations of cutting speed, feed rate, and depth of cut parameters with a selected range of parameters to simulate finishing operations. Temperature contour from finite element analysis showed that the highest temperature occurs near the depth of cut line just before the chip separates from the workpiece. Using multiple linear regression, a quadratic polynomial model is developed for maximum cutting force and a linear polynomial model peak tool temperature response respectively. Analysis of Variance (ANOVA) showed that feed rate had the most significance for cutting force followed by depth of cut. Also, cutting speed was found to have little influence. For peak tool temperature, cutting speed was the most significant cutting parameter followed by feed rate and depth of cut.

Optimization of surface roughness in ball-end milling using teaching-learning-based optimization and response surface methodology

2016 ◽  
Vol 231 (14) ◽  
pp. 2596-2607 ◽  
Author(s):  
Mithilesh K Dikshit ◽  
Asit B Puri ◽  
Atanu Maity
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Radial Depth ◽  
Teaching Learning Based Optimization ◽  
Teaching Learning ◽  
Axial Depth

Surface roughness is one of the most important requirements of the finished products in machining process. The determination of optimal cutting parameters is very important to minimize the surface roughness of a product. This article describes the development process of a surface roughness model in high-speed ball-end milling using response surface methodology based on design of experiment. Composite desirability function and teaching-learning-based optimization algorithm have been used for determining optimal cutting process parameters. The experiments have been planned and conducted using rotatable central composite design under dry condition. Mathematical model for surface roughness has been developed in terms of cutting speed, feed per tooth, axial depth of cut and radial depth of cut as the cutting process parameters. Analysis of variance has been performed for analysing the effect of cutting parameters on surface roughness. A second-order full quadratic model is used for mathematical modelling. The analysis of the results shows that the developed model is adequate enough and good to be accepted. Analysis of variance for the individual terms revealed that surface roughness is mostly affected by the cutting speed with a percentage contribution of 47.18% followed by axial depth of cut by 10.83%. The optimum values of cutting process parameters obtained through teaching-learning-based optimization are feed per tooth ( fz) = 0.06 mm, axial depth of cut ( Ap) = 0.74 mm, cutting speed ( Vc) = 145.8 m/min, and radial depth of cut ( Ae) = 0.38 mm. The optimum value of surface roughness at the optimum parametric setting is 1.11 µm and has been validated by confirmation experiments.

scholarly journals Experimental and Mathematical Modeling for Prediction of Tool Wear on the Machining of Aluminium 6061 Alloy by High Speed Steel Tools

2017 ◽  
Vol 7 (1) ◽  
pp. 461-469 ◽  
Author(s):  
Imhade Princess Okokpujie ◽  
Omolayo M. Ikumapayi ◽  
Ugochukwu C. Okonkwo ◽  
Enesi Y. Salawu ◽  
Sunday A. Afolalu ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Radial Depth ◽  
Machining Parameter ◽  
Axial Depth

AbstractIn recent machining operation, tool life is one of the most demanding tasks in production process, especially in the automotive industry. The aim of this paper is to study tool wear on HSS in end milling of aluminium 6061 alloy. The experiments were carried out to investigate tool wear with the machined parameters and to developed mathematical model using response surface methodology. The various machining parameters selected for the experiment are spindle speed (N), feed rate (f), axial depth of cut (a) and radial depth of cut (r). The experiment was designed using central composite design (CCD) in which 31 samples were run on SIEG 3/10/0010 CNC end milling machine. After each experiment the cutting tool was measured using scanning electron microscope (SEM). The obtained optimum machining parameter combination are spindle speed of 2500 rpm, feed rate of 200 mm/min, axial depth of cut of 20 mm, and radial depth of cut 1.0mm was found out to achieved the minimum tool wear as 0.213 mm. The mathematical model developed predicted the tool wear with 99.7% which is within the acceptable accuracy range for tool wear prediction.

Tool Wear Analysis in End Milling of Advanced Ceramics with TiAlN and TiN Coated Carbide Inserts

2012 ◽  
Vol 576 ◽  
pp. 76-79
Author(s):  
M. Mohan Reddy ◽  
Alexander Gorin ◽  
Khaled A. Abou-El-Hossein ◽  
D. Sujan ◽  
Mohammad Yeakub Ali ◽  
...  
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
End Milling ◽  
Cutting Speed ◽  
High Hardness ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Coated Carbide ◽  
Axial Depth

Advanced ceramic materials are difficult to machine by conventional methods due to the brittle nature and high hardness. The appropriate selection of cutting tool and cutting conditions may help to improve machinability by endmilling. Performance of TiAlN and TiN coated carbide tool insert in end milling of machinable glass ceramic has been investigated. Several dry cutting tests were performed to select the optimum cutting parameters for the endmilling in order to obtain better tool life. In this work, a study was carried out on the influence of cutting speed, feed rate and axial depth of cut on tool wear.The technique of design of experiments (DOE) was used for the planning and analysis of the experiments. Tool wear prediction model was developed using Response surface methodology.The results indicate that tool wear increased with increasing the cutting speed and axial depth of cut. Effect of feed rate is not much significant on selected range of cutting condition

The effect of fiber orientation on mechanical properties and machinability of GFRP composites by end milling using cutting force analysis

2021 ◽  
pp. 096739112199128
Author(s):  
Abburi Lakshman Kumar ◽  
M Prakash
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Fiber Orientation ◽  
End Milling ◽  
Cutting Speed ◽  
Fiber Material ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Gfrp Composites ◽  
Gfrp Composite

In recent years, glass fiber-reinforced polymer (GFRP) composite materials have become a viable alternative material for different engineering applications due to their superior/excellent properties. The strength of the composite is positively related to the orientation of the fiber material. However, the machinability is still a problem when components are manufactured using the GFRP composites due to their anisotropic properties. The aim of this analytical research paper is to investigate the influence of fiber orientation on the strength and machinability in slot milling of GFRP fabricated using the vacuum infusion method. The fiber orientations of 0°/90° and ±45° are used for the fabrication of GFRP composite laminates. The experiments were conducted using an orthogonal array. Analysis of variance was employed to determine the influence of milling parameters such as cutting speed, transverse feed rate, and axial depth of cut (A.D.O.C.) for the surface finish (Ra), cutting force, and Machinability index (MI). The MI is calculated based on specific cutting pressure. The influence of fiber orientation on the cutting force and surface topography was analyzed. It was concluded that the cutting forces were significantly influenced by the fiber orientation and not affected by the machining parameters. The results revealed that the transverse feed rate was the primary influencing parameter responsible for the increase in MI (40 to 56%). The A.D.O.C. was accountable for the increase in cutting force (55 to 94%). Similarly, the cutting speed influenced Ra, which increased from 17 to 37%.

Micro Flat End Milling Simulation Model With Instantaneous Plowing Area Prediction

2016 ◽  
Vol 4 (2) ◽  
Author(s):  
Abdolreza Bayesteh ◽  
Junghyuk Ko ◽  
Martin Byung-Guk Jun
Keyword(s):  
Feed Rate ◽  
Tool Path ◽  
End Milling ◽  
Chip Thickness ◽  
Depth Of Cut ◽  
Uncut Chip Thickness ◽  
Chip Area ◽  
Edge Radius ◽  
Wide Range ◽  
Radial Depth

There is an increasing demand for product miniaturization and parts with features as low as few microns. Micromilling is one of the promising methods to fabricate miniature parts in a wide range of sectors including biomedical, electronic, and aerospace. Due to the large edge radius relative to uncut chip thickness, plowing is a dominant cutting mechanism in micromilling for low feed rates and has adverse effects on the surface quality, and thus, for a given tool path, it is important to be able to predict the amount of plowing. This paper presents a new method to calculate plowing volume for a given tool path in micromilling. For an incremental feed rate movement of a micro end mill along a given tool path, the uncut chip thickness at a given feed rate is determined, and based on the minimum chip thickness value compared to the uncut chip thickness, the areas of plowing and shearing are calculated. The workpiece is represented by a dual-Dexel model, and the simulation properties are initialized with real cutting parameters. During real-time simulation, the plowed volume is calculated using the algorithm developed. The simulated chip area results are qualitatively compared with measured resultant forces for verification of the model and using the model, effects of cutting conditions such as feed rate, edge radius, and radial depth of cut on the amount of shearing and plowing are investigated.

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