Modeling and Prediction of Cutting Noise in the Face-Milling Process

2007 ◽  
Vol 129 (3) ◽  
pp. 527-530 ◽  
Author(s):  
Karthikeyan Sampath ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Aerodynamic Noise ◽  
Noise Prediction ◽  
Vibration Data ◽  
Total Noise ◽  
Workpiece Vibration ◽  
The Face

A cutting noise prediction model is developed to relate the cutter-workpiece vibrations to the sound pressure field around the cutter in the high-speed face-milling process. The cutter-workpiece vibration data are obtained from a dynamic mechanistic face-milling force simulation model. The total noise predicted, based on both cutting noise and aerodynamic noise prediction, compares well to the noise observed experimentally in the face-milling process. Using the model, the effects of various machining and cutter geometry parameters are studied. It is shown that cutter geometry, machine dynamics, and cutting speed all play important roles in determining overall noise in face milling.

scholarly journals Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

2021 ◽  
pp. 71-84
Author(s):  
Nhu-Tung Nguyen ◽  
Dung Hoang Tien ◽  
Nguyen Tien Tung ◽  
Nguyen Duc Luan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
High Speed Milling

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

Structure Dynamic Modification and Optimization for High-Speed Face Milling Cutter

2004 ◽  
Vol 471-472 ◽  
pp. 663-667 ◽  
Author(s):  
Wei Xiao Tang ◽  
Xing Ai ◽  
H.Y. Wu ◽  
Song Zhang ◽  
H. Jiang
Keyword(s):  
High Speed ◽  
Milling Process ◽  
Face Milling ◽  
Relative Speed ◽  
Structural Dynamic ◽  
High Speed Milling ◽  
Structural Dynamic Modification ◽  
The Face ◽  
Dynamic Modification ◽  
The Stability

Due to the complexity of high-speed milling process by high relative speed and interrupted cutting, the face milling cutters possess the multi-order modes and the vibrating displacements of the cutting edges under each modes affect adversely both the surface roughness and the life of machine/tool system worse than other structures. In order to improve the stability of milling process, this work focuses on the influence of the variables such as structure geometries and constraint conditions on the eigenfrequencies and modeshapes of cutter. As an example, the dynamic characteristics of several face cutters are analyzed and optimized by structural dynamic modification (SDM) techniques.

Research on Dynamic Cutting Performance of High Speed Face Milling Cutter

2008 ◽  
Vol 375-376 ◽  
pp. 663-666
Author(s):  
Min Li Zheng ◽  
Bin Jiang ◽  
Jia Liu ◽  
Chong Yu He
Keyword(s):  
Contact Angle ◽  
Aluminum Alloy ◽  
Frequency Spectrum ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Cutting Performance ◽  
Milling Cutter

According to the characteristics of high speed face milling process, the models of dynamic cutting forces and frequency spectrum were established. By means of frequency spectrum analysis for dynamic cutting forces of high speed face milling cutter, the law of influence of cutter’s structure and parameters on dynamic cutting performance of cutter was acquired, high speed face milling cutter for machining aluminum alloy was developed, and evaluation for dynamic cutting performance of cutter was processed based on experiment. The results indicate that more teeth of cutter and greater cutting contact angle can make the energy more dispersible, higher cutting speed and greater rake of cutter can depress dynamic cutting forces, and improve effectively dynamic cutting performance of cutter. High speed face milling cutter with five teeth takes on better dynamic high speed cutting performance for machining aluminum alloy, as cutting contact angle exceeds ninety degrees but it is less than one hundred eighty degrees, and cutting speed exceeds 2260m/min.

Experimental study on the chip morphology, tool–chip contact length, workpiece vibration, and surface roughness during high-speed face milling of A6061 aluminum alloy

2019 ◽  
Vol 234 (3) ◽  
pp. 610-620 ◽  
Author(s):  
Thi-Hoa Pham ◽  
Duc-Toan Nguyen ◽  
Tien-Long Banh ◽  
Van-Canh Tong
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Contact Length ◽  
Face Milling ◽  
Cutting Conditions ◽  
Workpiece Vibration

In this study, experiments of high-speed face milling of A6061 aluminum alloy with a carbide insert milling cutter under dry cutting conditions were conducted. The contact length between tool and chip, the workpiece vibration amplitude, and the arithmetic average surface roughness were measured under varying cutting conditions (cutting speed, feed rate, and depth of cut). The characteristics of chip morphology were observed using scanning electron microscope. Experimental results showed that the increasing cutting speed reduced the tool–chip contact length, the workpiece vibration, and the surface roughness. The tool–chip contact length, the workpiece vibration, and the surface roughness were all increased with increasing cutting depth and feed rate. The results of chip morphology showed that the chips with serrated form were generated under high-speed cutting conditions. Moreover, scratch lines, plastic deformation cavities, and local molten chip material were observed on the slide chip surface.

Multi-objective optimization in face milling process with cryogenic cooling using grey fuzzy analysis and BPNN-GA methods

2019 ◽  
Vol 36 (5) ◽  
pp. 1542-1565 ◽  
Author(s):  
Bobby Oedy Pramoedyo Soepangkat ◽  
Rachmadi Norcahyo ◽  
Bambang Pramujati ◽  
M. Abdul Wahid
Keyword(s):  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Cryogenic Cooling ◽  
Performance Characteristics ◽  
Depth Of Cut ◽  
Content Type ◽  
Fuzzy Analysis ◽  
Milling Parameters ◽  
The Face

Purpose The purpose of this study is to investigate the prediction and optimization of multiple performance characteristics in the face milling process of tool steel ASSAB XW-42. Design/methodology/approach The face milling parameters (cutting speed, feed rate and axial depth of cut) and flow rate (FR) of cryogenic cooling were optimized with consideration of multiple performance characteristics, i.e. surface roughness (SR), cutting force (Fc) and metal removal rate (MRR). FR of cryogenic cooling has two levels, whereas the three face milling parameters each have three levels. Using Taguchi method, an L18 mixed-orthogonal array was selected as the design of experiments. The rough estimation of the optimum face milling parameters was determined by using grey fuzzy analysis. The global optimum face milling parameters were searched by applying the backpropagation neural network-based genetic algorithm (BPNN-GA) method. Findings The optimum SR, cutting force (Fc) and MRR could be obtained by setting FR, cutting speed, feed rate and axial depth of cut at 0.5 l/min, 280 m/min, 90 mm/min and 0.2 mm, respectively. The experimental confirmation results showed that BPNN-based GA optimization method could accurately predict and significantly improve all of the multiple performance characteristics. Originality/value To the best of the authors’ knowledge, there were no publications available regarding multi-response optimization using the combination of grey fuzzy analysis and BPNN-based GA methods during cryogenically face milling process.

Optimization of High Speed Milling Cutter Based on Critical Cutting Speed

2008 ◽  
Vol 392-394 ◽  
pp. 793-797
Author(s):  
Bin Jiang ◽  
Min Li Zheng ◽  
Fang Xu
Keyword(s):  
High Speed ◽  
Influencing Factor ◽  
Cutting Speed ◽  
Optimization Method ◽  
Face Milling ◽  
Cutting Performance ◽  
Feed Speed ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Cutting Heat

Based on analyses of cutting heat and temperature in high speed milling, to construct a model of critical cutting speed for high speed milling cutter, find out influencing factor of critical cutting speed, and put forward optimization method of high speed milling cutter based on critical cutting speed. The results indicate that chip conducts a majority of cutting heat along with increase of cutting speed, feed speed and the rake of cutter. Cutting heat which workpiece conducts gradually diminishes when heat source accelerates. When cutting performance of cutter satisfies requirements of high speed milling, the proportion of cutting heat which workpiece conducts approaches its maximum as cutting speed comes to critical cutting speed. To optimize high speed face milling cutter for machining aluminum alloy according to critical cutting speed, the cutter takes on better cutting performance when cutting speed is 2040m/min~2350m/min.

Effect of Cutting Speed on the Face Milling of CFRP Using a PCD Tool

2016 ◽  
Vol 874 ◽  
pp. 487-491
Author(s):  
Takayuki Kitajima ◽  
Takumi Horiuchi ◽  
Akinori Yui ◽  
Yosuke Ito
Keyword(s):  
Mechanical Characteristics ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Face Milling ◽  
Fiber Reinforced Plastic ◽  
Pcd Tool ◽  
Reinforced Plastic ◽  
The Face ◽  
Cutting Speeds

Carbon-fiber-reinforced plastic (CFRP) is used in various industries such as aerospace and automobile industries because of its high mechanical characteristics. However, this material is difficult to cut. Tool wear and delamination frequently occur during the drilling or cutting of CFRP. In previous studies, we developed a CFRP cutting tool using polycrystalline diamond (PCD). The PCD tool exhibited excellent cutting performance at cutting speeds as low as <120 m/min. In this study, the authors investigated the effect of cutting speed on the face milling of CFRP by using the developed PCD tool.

scholarly journals Research and Optimization of Surface Roughness in Milling of SLM Semi-Finished Parts Manufactured by Using the Different Laser Scanning Speed

Materials ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 9 ◽  
Author(s):  
Andrzej Matras
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Laser Scanning ◽  
Cutting Tool ◽  
Scanning Speed ◽  
Milling Process ◽  
Face Milling ◽  
Machining Parameters ◽  
The Face ◽  
Laser Scanning Speed

The paper studies the potential to improve the surface roughness in parts manufactured in the Selective Laser Melting (SLM) process by using additional milling. The studied process was machining of samples made of the AlSi10Mg alloy powder. The simultaneous impacts of the laser scanning speed of the SLM process and the machining parameters of the milling process (such as the feed rate and milling width) on the surface roughness were analyzed. A mathematical model was created as a basis for optimizing the parameters of the studied processes and for selecting the sets of optimum solutions. As a result of the research, surface with low roughness (Ra = 0.14 μm, Rz = 1.1 μm) was obtained after the face milling. The performed milling allowed to reduce more than 20-fold the roughness of the SLM sample surfaces. The feed rate and the cutting width increase resulted in the surface roughness deterioration. Some milled surfaces were damaged by the chip adjoining to the rake face of the cutting tool back tooth.

scholarly journals FPGA Based Real Time Simulations of the Face Milling Process

IEEE Access ◽  
2020 ◽  
Vol 8 ◽  
pp. 215987-216002
Author(s):  
Michal R. Mazur ◽  
Marek A. Galewski ◽  
Krzysztof J. Kalinski
Keyword(s):  
Real Time ◽  
Milling Process ◽  
Face Milling ◽  
The Face ◽  
Real Time Simulations

scholarly journals Analysis of the Face Milling Process Based on the Imitation Modelling

2016 ◽  
Vol 126 ◽  
pp. 012001 ◽  
Author(s):  
V A Khomenko ◽  
A O Cherdancev ◽  
P O Cherdancev ◽  
V D Goncharov ◽  
A Kulawik
Keyword(s):  
Milling Process ◽  
Face Milling ◽  
The Face
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