Modelling of surface roughness in inclined milling operations with circle-segment end mills

2018 ◽  
Vol 84 ◽  
pp. 161-176 ◽  
Author(s):  
G. Urbikain ◽  
L.N. López de Lacalle
Keyword(s):  
Surface Roughness ◽  
Milling Operations ◽  
End Mills

scholarly journals Wear Behavior of Uncoated and Coated Tools in Milling Operations of AMPCO (Cu-Be) Alloy

2021 ◽  
Vol 11 (16) ◽  
pp. 7762
Author(s):  
Vitor F. C. Sousa ◽  
João Castanheira ◽  
Francisco J. G. Silva ◽  
José S. Fecheira ◽  
Gustavo Pinto ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Wear Behavior ◽  
Cutting Tools ◽  
Machining Performance ◽  
Machining Processes ◽  
Coated Tools ◽  
Milling Operations ◽  
Cutting Length ◽  
Solid Carbide ◽  
End Mills

Copper-Beryllium alloys have excellent wear resistance and high mechanical properties, they also possess good electrical and thermal conductivity, making these alloys very popular in a wide variety of industries, such as aerospace, in the fabrication of tools for hazardous environments and to produce injection molds and mold inserts. However, there are some problems in the processing of these alloys, particularly when these are subject to machining processes, causing tools to deteriorate quite rapidly, due to material adhesion to the tool’s surface, caused by the material’s ductile nature. An assessment of tool-wear after machining Cu-Be alloy AMPCOLOY 83 using coated and uncoated tools was performed, offering a comparison of the machining performance and wear behavior of solid-carbide uncoated and DLC/CrN multilayered coated end-mills with the same geometry. Multiple machining tests were conducted, varying the values for feed and cutting length. In the initial tests, cutting force values were registered. The material’s surface roughness was also evaluated and the cutting tools’ edges were subsequently analyzed, identifying the main wear mechanisms and how these developed during machining. The coated tools exhibited a better performance for shorter cutting lengths, producing a lower degree of roughness on the surface on the machined material. The wear registered for these tools was less intense than that of uncoated tools, which suffered more adhesive and abrasive damage. However, it was observed that, for greater cutting lengths, the uncoated tool performed better in terms of surface roughness and sustained wear.

INVESTIGATION OF WIPER INSERTS EFFECTS IN TURNING AND MILLING PROCESSES

2021 ◽  
pp. 2150111
Author(s):  
MURAT KIYAK
Keyword(s):  
Surface Roughness ◽  
Cost Saving ◽  
Tool Wear ◽  
Feed Rate ◽  
Turning Process ◽  
Nose Radius ◽  
Turning Operations ◽  
Effective Factors ◽  
Milling Operations ◽  
The Many

The surface roughness is a crucial factor in machining methods. The most effective factors on surface roughness are feed rate and tool nose radius. Due to the many advantages of wiper (multi-nose radius) inserts, their importance and use has been increasing recently. The purpose of this paper is to investigate the effect of wiper inserts on surface roughness and tool wear. In this study, conventional inserts and wiper inserts were experimentally compared separately in milling and turning operations. Compared to conventional inserts, the surface roughness values obtained using wiper inserts improved by 33% in turning operations and approximately 40% in milling operations. It was observed that the production time in the turning process was reduced by about 25% in the case of using wiper inserts compared to the use of conventional inserts. In milling, this ratio was determined to be approximately 43% due to the fact that it has multiple cutting edge. It has been observed that the use of wiper inserts in machining methods creates a significant time and cost saving advantage.

scholarly journals Influence of DLC Coatings Deposited by PECVD Technology on the Wear Resistance of Carbide End Mills and Surface Roughness of AlCuMg2 and 41Cr4 Workpieces

Coatings ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1038
Author(s):  
Sergey N. Grigoriev ◽  
Marina A. Volosova ◽  
Sergey V. Fedorov ◽  
Mikhail Mosyanov
Keyword(s):  
Surface Roughness ◽  
Wear Resistance ◽  
Aluminum Alloy ◽  
Carbon Steel ◽  
Structural Characteristics ◽  
Low Carbon Steel ◽  
Single Layer ◽  
Chemical Vapor ◽  
Low Carbon ◽  
End Mills

The primary purpose of this work was to study the effectiveness of using diamond-like coatings (DLC) to increase the wear resistance of carbide end mills and improve the surface quality of the processed part when milling aluminum alloy and low-carbon steel. The functional role of forming an adhesive sublayer based on (CrAlSi)N immediately before the application of the external DLC film by plasma-enhanced chemical vapor deposition (PECVD) technology in the composition of a multicomponent gas mixture containing tetramethylsilane was established in the article. The article shows the degree of influence of the adhesive sublayer on important physical, mechanical, and structural characteristics of DLCs (hardness, modulus of elasticity, index of plasticity, and others). A quantitative assessment of the effect of single-layer DLCs and double-layer (CrAlSi)N/DLCs on the wear rate of end mills during operation and the surface roughness of machined parts made of aluminum alloy AlCuMg2 and low-carbon steel 41Cr4 was performed.

scholarly journals Optimization of cutting conditions using artificial neural networks and the Edgeworth-Pareto method for CNC face-milling operations on high-strength grade-H steel

2019 ◽  
Vol 105 (5-6) ◽  
pp. 2151-2165 ◽  
Author(s):  
Adel Taha Abbas ◽  
Danil Yurievich Pimenov ◽  
Ivan Nikolaevich Erdakov ◽  
Tadeusz Mikolajczyk ◽  
Mahmoud Sayed Soliman ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Unit Volume ◽  
High Strength ◽  
Face Milling ◽  
Production Costs ◽  
The Other ◽  
Cutting Conditions ◽  
Milling Operations ◽  
Artificial Neural ◽  
Pareto Method

Abstract Computer Numerical Control (CNC) face milling is commonly used to manufacture products from high-strength grade-H steel in both the automotive and the construction industry. The various milling operations for these components have key performance indicators: accuracy, surface roughness (Ra), and machining time for removal of a unit volume min/cm3 (Tm). The specified surface roughness values for machining each component is achieved based on the prototype specifications. However, poor adherence to specifications can result in the rejection of the machined parts, implying extra production costs and raw material wastage. An algorithm using an artificial neural network (ANN) with the Edgeworth-Pareto method is presented in this paper to optimize the cutting parameter in CNC face-milling operations. The set of parameters are adjusted to improve surface roughness and minimal unit-volume material removal rates, thereby reducing production costs and improving accuracy. An ANN algorithm is designed in Matlab, based on a 3–10-1 Multi-Layer Perceptron (MLP), which predicts the Ra of the workpiece surface to an accuracy of ± 5.78% within the range of the experimental angular spindle speed, feed rate, and cutting depth. An unprecedented Pareto frontier for Ra and Tm was obtained for the finished grade-H steel workpiece using an ANN algorithm that was then used to determine optimized cutting conditions. Depending on the production objective, one or the other of two sets of optimum machining conditions can be used: the first one sets a minimum cutting power, while the other sets a maximum Tm with a slight increase (under 5%) in milling costs.

ANALYSIS OF THE CORRELATION BETWEEN FRACTAL STRUCTURE OF CUTTING FORCE SIGNAL AND SURFACE ROUGHNESS OF MACHINED WORKPIECE IN END MILLING OPERATION

Fractals ◽  
2019 ◽  
Vol 27 (02) ◽  
pp. 1950013 ◽  
Author(s):  
AHMAD THUFFAIL THASTHAKEER ◽  
ALI AKHAVAN FARID ◽  
CHANG TECK SENG ◽  
HAMIDREZA NAMAZI
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
Cutting Forces ◽  
End Milling ◽  
Complex Structure ◽  
Machined Surface ◽  
End Mills ◽  
Machining Operations

Analysis of the machined surface is one of the major issues in machining operations. On the other hand, investigating about the variations of cutting forces in machining operation has great importance. Since variations of cutting forces affect the surface quality of machined workpiece, therefore, analysis of the correlation between cutting forces and surface roughness of machined workpiece is very important. In this paper, we employ fractal analysis in order to investigate about the complex structure of cutting forces and relate them to the surface quality of machined workpiece. The experiments have been conducted in different conditions that were selected based on cutting depths, type of cutting tool (serrated versus. square end mills) and machining conditions (wet and dry machining). The result of analysis showed that among all comparisons, we could only see the correlation between complex structure of cutting force and the surface roughness of machined workpiece in case of using serrated end mill in wet machining condition. The employed methodology in this research can be widely applied to other types of machining operations to analyze the effect of variations of different parameters on variability of cutting forces and surface roughness of machined workpiece and then investigate about their correlation.

Improvement of surface roughness models for face milling operations through dimensionality reduction

2012 ◽  
Vol 19 (2) ◽  
pp. 179-197 ◽  
Author(s):  
Maciej Grzenda ◽  
Andres Bustillo ◽  
Guillem Quintana ◽  
Joaquim Ciurana
Keyword(s):  
Surface Roughness ◽  
Dimensionality Reduction ◽  
Face Milling ◽  
Milling Operations

Boosting Projections to improve surface roughness prediction in high-torque milling operations

2012 ◽  
Vol 16 (8) ◽  
pp. 1427-1437 ◽  
Author(s):  
José-Francisco Díez-Pastor ◽  
Andres Bustillo ◽  
Guillem Quintana ◽  
César García-Osorio
Keyword(s):  
Surface Roughness ◽  
Surface Roughness Prediction ◽  
Milling Operations ◽  
Roughness Prediction ◽  
High Torque

Vortex Tube Impact on Cooling Milling Machining

2012 ◽  
Author(s):  
Basel Alsayyed ◽  
Mohammad O. Hamdan ◽  
Saud Aldajah
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Vortex Tube ◽  
Compressed Air ◽  
Heat Map ◽  
Milling Operations ◽  
Three Samples ◽  
Cutting Operation ◽  
Water Base ◽  
Vortex Tubes

In this paper, the authors will present the use of a vortex tube in cooling milling operations. The focuses will be regarding the surface finish and temperature of the tool during the cutting operation. Three cooling setups, cutting without coolant, cooling with a water base traditional coolant, and cooling with vortex tube will be compared. A Flir E320 UV camera has been used to capture the heat map around the tool during the cutting process. The surface roughness has been measured and analysed for all three samples using Taylor/Hobson Precision Surtronc 3+ apparatus. The findings of this study have shown comparative efficient cooling using the vortex tubes. The vortex tube cooling is also cleaner and can be directed in such a way to collect the chips as they develop with the least mess or no mess. Vortex tubes have no moving parts, and it is very much maintenance free device. Compressed air is needed to feed the vortex tube, which is available usually in any machine shop.

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