Characterizing the Effect of Cutting Condition, Tool Path, and Heat Treatment on Cutting Forces of Selective Laser Melting Spherical Component in Five-Axis Milling

2018 ◽  
Vol 140 (5) ◽  
Author(s):  
Amir Mahyar Khorasani ◽  
Ian Gibson ◽  
Moshe Goldberg ◽  
Guy Littlefair
Keyword(s):  
Heat Treatment ◽  
Production Process ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Tool Path ◽  
Annealing Temperature ◽  
Spindle Speed ◽  
Cutting Condition ◽  
Scallop Height

Additive manufacturing (AM), partly due to its compatibility with computer-aided design (CAD) and fabrication of intricate shapes, is an emerging production process. Postprocessing, such as machining, is particularly necessary for metal AM due to the lack of surface quality for as-built parts being a problem when using as a production process. In this paper, a predictive model for cutting forces has been developed by using artificial neural networks (ANNs). The effect of tool path and cutting condition, including cutting speed, feed rate, machining allowance, and scallop height, on the generated force during machining of spherical components such as prosthetic acetabular shell was investigated. Also, different annealing processes like stress relieving, mill annealing and β annealing have been carried out on the samples to better understand the effect of brittleness, strength, and hardness on machining. The results of this study showed that ANN can accurately apply to model cutting force when using ball nose cutters. Scallop height has the highest impact on cutting forces followed by spindle speed, finishing allowance, heat treatment/annealing temperature, tool path, and feed rate. The results illustrate that using linear tool path and increasing annealing temperature can result in lower cutting force. Higher cutting force was observed with greater scallop height and feed rate while for higher finishing allowance, cutting forces decreased. For spindle speed, the trend of cutting force was increasing up to a critical point and then decreasing due to thermal softening.

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%.

Effect of the Cutting Velocity and Heat Treatment on Turning Cutting Forces of an SMA Cu-Al-Be Alloys

2013 ◽  
Vol 758 ◽  
pp. 157-164
Author(s):  
Francisco Valdenor Pereira da Silva ◽  
José Paulo Vogel ◽  
Rodinei Medeiros Gomes ◽  
Tadeu Antonio de Azevedo Melo ◽  
Anna Carla Araujo ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Shape Memory Alloys ◽  
Shape Memory ◽  
Cutting Force ◽  
Shape Memory Effect ◽  
Memory Effect ◽  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Velocity ◽  
Resultant Forces

This work studies the effect of heat treatment and cutting velocities on machining cutting forces in turning of a Cu-11.8%Al-0.55%Be shape memory alloys. The heat treatment was performed to obtain samples with austenite and martensite microstructures. Cutting force was investigated using a 3-component dynamometer in several revolutions and data were analyzed using statistic tools. It was found that the resultant forces were higher in quenched alloy due to the presence of Shape Memory Effect. Chip formation occurred in a shorter time in the sample without the Shape Memory Effect.

scholarly journals The Influence of Tool Path Strategies on Cutting Force and Surface Texture during Ball End Milling of Low Curvature Convex Surfaces

2014 ◽  
Vol 2014 ◽  
pp. 1-14 ◽  
Author(s):  
Shaghayegh Shajari ◽  
Mohammad Hossein Sadeghi ◽  
Hamed Hassanpour
Keyword(s):  
Cutting Force ◽  
Surface Texture ◽  
Cutting Forces ◽  
Tool Path ◽  
End Milling ◽  
Cutting Speed ◽  
Quality Level ◽  
Convex Surfaces ◽  
Freeform Surface Machining ◽  
Selection Of

Advancement in machining technology of curved surfaces for various engineering applications is increasing. Various methodologies and computer tools have been developed by the manufacturers to improve efficiency of freeform surface machining. Selection of the right sets of cutter path strategies and appropriate cutting conditions is extremely important in ensuring high productivity rate, meeting the better quality level, and lower cutting forces. In this paper, cutting force as a new decision criterion for the best selection of tool paths on convex surfaces is presented. Therefore, this work aims at studying and analyzing different finishing strategies to assess their influence on surface texture, cutting forces, and machining time. Design and analysis of experiments are performed by means of Taguchi technique and analysis of variance. In addition, the significant parameters affecting the cutting force in each strategy are introduced. Machining strategies employed include raster, 3D-offset, radial, and spiral. The cutting parameters were feed rate, cutting speed, and step over. The experiments were carried out on low curvature convex surfaces of stainless steel 1.4903. The conclusion is that radial strategy provokes the best surface texture and the lowest cutting forces and spiral strategy signifies the worst surface texture and the highest cutting forces.

The Effect of Cutting Force Vibration on Machining Quality for Reaming ZL102 Alloy with PCD Step Reamer

2018 ◽  
Vol 764 ◽  
pp. 279-290
Author(s):  
X.D. Wang ◽  
W.L. Ge ◽  
Y.G. Wang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Cutting Forces ◽  
Thrust Force ◽  
Maximum Amplitude ◽  
Spindle Speed ◽  
Machining Process ◽  
Cutting Fluid ◽  
Hole Quality ◽  
Force Vibration

The characteristics of cutting forces vibration and its effects to the hole quality in reaming aluminum cast alloy using a poly-crystalline diamond (PCD) step reamer in dry and wet conditions were studied. First, centrifugal force vibration model of the PCD step reamer during machining process was established and through the analysis of the model, it can be concluded that the maximum amplitude of the vibration is positively related to the angular velocity of the reamer. Then, thrust force and cutting torque were measured by a Kistler Dynamometer during reaming process and these vibration frequency and amplitude were analyzed by fast Fourier transformation (FFT). Hole quality was evaluated by hole diameter and surface roughness. Results show that, as the spindle speed increases, the stability of thrust force and cutting torque deteriorates gradually, and there was a severe vibration in the cutting force and the surface roughness when the spindle speed reached 10000 rpm in wet and 7000 rpm in dry cutting conditions. Compared the variation of hole surface roughness and vibration characteristic of cutting forces, it can be observed that the trends are very consistent, the surface roughness deteriorates when cutting forces become unstable. Therefore,the cutting forces stability was an important factor that influence the hole quality. Cutting fluid has a positive effect to stabilize the reaming process and was beneficial to improve the hole quality.

scholarly journals Development Research on Integrating CNC Machine Tool with Plasma for Online Surface Heat Treatment

2021 ◽  
Vol 2021 ◽  
pp. 1-14
Author(s):  
Shao-Hsien Chen ◽  
Bo-Ting Wang
Keyword(s):  
Heat Treatment ◽  
Real Time ◽  
Feed Rate ◽  
Surface Hardness ◽  
Spindle Speed ◽  
Experimental Results ◽  
Machining Process ◽  
Cnc Machine ◽  
Optimum Parameters ◽  
Hardening Effect

In this study, the plasma was integrated with a lathe, and the online heat treatment was performed to achieve mechanical strength and hardness, to reduce the machining process and handling. However, for online heat treatment of cast iron FC25, it is important to study the parameters of the lathe and plasma, and the research method is used eventually to optimize the process and reduce the machining cost and machining error. The variable factors in the surface online real-time heat treatment are spindle speed, feed rate, and current, and the objective function is the hardness of mechanical properties. In the screening experiment, the interaction of factors was discussed using a full factorial experiment. The Central Composite Design was combined with the Lack-of-Fit test for the optimization experiment, and the R2 coefficient was used to determine whether the regression model is appropriate. The optimum parameters were derived from the contour diagram and response surface diagram. The experimental results show that the significant factors include spindle speed, feed rate, and current and the optimum parameters include spindle speed of 168 rpm, feed rate of 0.068 mm/rev, and current of 86 A. The experimental results of optimum parameters show that the surface hardness is increased from 306 HLD to 806 HLD and the surface hardening effect is enhanced by 163%, so the online real-time heat treatment equipment has the best hardening effect.

scholarly journals Effects of Turning Parameters and Parametric Optimization of the Cutting Forces in Machining SiCp/Al 45 wt% Composite

Metals ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 840 ◽  
Author(s):  
Rashid Ali Laghari ◽  
Jianguang Li ◽  
Mozammel Mia
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Desirability Function ◽  
Interactive Effect ◽  
Cutting Speed ◽  
Experimental Results ◽  
Machining Process ◽  
Depth Of Cut

Cutting force in the machining process of SiCp/Al particle reinforced metal matrix composite is affected by several factors. Obtaining an effective mathematical model for the cutting force is challenging. In that respect, the second-order model of cutting force has been established by response surface methodology (RSM) in this study, with different cutting parameters, such as cutting speed, feed rate, and depth of cut. The optimized mathematical model has been developed to analyze the effect of actual processing conditions on the generation of cutting force for the turning process of SiCp/Al composite. The results show that the predicted parameters by the RSM are in close agreement with experimental results with minimal error percentage. Quantitative evaluation by using analysis of variance (ANOVA), main effects plot, interactive effect, residual analysis, and optimization of cutting forces using the desirability function was performed. It has been found that the higher depth of cut, followed by feed rate, increases the cutting force. Higher cutting speed shows a positive response by reducing the cutting force. The predicted and experimental results for the model of SiCp/Al components have been compared to the cutting force of SiCp/Al 45 wt%—the error has been found low showing a good agreement.

Cutting force, Vibration, and Temperature in Drilling on a Thermoplastic Material of PEEK

2021 ◽  
pp. 089270572110523
Author(s):  
Dar-Yuan Chang ◽  
Chien-Hung Lin ◽  
Xing-Yao Wu ◽  
Chun-Chun Yang ◽  
Shan-Chao Chou
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Spindle Speed ◽  
Thermoplastic Material ◽  
Low Level ◽  
Multiple Sensors ◽  
Acceleration Amplitude ◽  
The Time Domain ◽  
High Level ◽  
Machining Characteristics

Polyetheretherketone (PEEK) is one of the semi-crystalline thermoplastic polymers with excellent machinability and chemical stability applied to precise structural plates and electronic components. This study installed multiple sensors to analyze the machining characteristics in the PEEK drilling. According to the time domain signals, the effects of spindle speed and feed rate on the machining characteristics of cutting force and vibration were investigated. In addition, an infrared thermography was installed to record the temperature variation within the drilling area. The experimental hole was 2-mm diameter with a 4.5-mm depth. Experimental results showed that the effect of the feed rate on thrust force is greater than the spindle speed; drilling by a low-level spindle speed with a low-level feed rate can obtain the smallest cutting force and acceleration amplitude in the spindle axis; the temperature within the drilling area is inverse to the feed rate and a high-level feed rate is helpful for forming regular curl chips. When adequate airflow was applied during the drilling operation, the hole’s shrinkage ratio and roundness can be decreased. The data presented in this paper provide valuable references for realizing the drilling of the thermoplastic—PEEK.

Minimum Time Trajectory Planning Along Specified Tool Path With Consideration of Cutting Force Constraint and Feed Drive Dynamics

Manufacturing ◽  
2002 ◽  
Author(s):  
Nejah Tounsi ◽  
Trevor E. Bailey ◽  
Mohamed A. Elbestawi
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Tool Path ◽  
End Milling ◽  
Low Frequency ◽  
Minimum Time ◽  
Force Model ◽  
Modeling And Analysis ◽  
Feed Drive ◽  
Drive Dynamics

This paper proposes an Optimized Feed Scheduling Strategy (OFSS). This strategy integrates the feed drive dynamics with the minimum-time trajectory planing to achieve the desired feed rate at the appropriate tool position along specified tool path. It optimizes the use of the feed drive capabilities and provides good tracking of the cutting geometry variations. The feed scheduling is applied to maintain near-constant cutting force magnitude. An integrated geometric and mechanistic force model is used to estimate the in-cut geometry and the cutting force. A methodology based on time series modeling and analysis is proposed to identify the low frequency feed drive dynamics. The resulting model is applied as an acceleration/deceleration processor (Acc/Dec) to relate the actual feed rate to the commanded feed rate specified in the G-Code file. The effectiveness of the OFSS is analyzed using ball end milling operations. Its performance in terms of productivity and machining safety is assessed based on comparison with other feed scheduling techniques where the trajectory planing does not consider the feed drive dynamics.

scholarly journals Drilling Burr Minimization by Changing Drill Geometry

Materials ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3207
Author(s):  
Emilia Franczyk ◽  
Łukasz Ślusarczyk ◽  
Wojciech Zębala
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Complete Elimination ◽  
Positive Correlation ◽  
Optimal Geometry ◽  
Burr Size ◽  
Specific Length

This article presents an attempt to solve the problem of the formation of burrs and drilling caps in the process of drilling in difficult-to-cut materials, specifically in the titanium alloy Ti-6Al-4V. In order to eliminate these phenomena, a chamfer of specific length and angle was made on FANAR drill’s margin. Taguchi and ANOVA methods were used to plan and analyze the experiment aimed at determining the optimal geometry of the modified drill. Chamfer with a length of 2 mm and an angle of 10° was selected. In the next stage of research, the values of cutting forces and burr heights obtained during drilling with the original and modified drill were compared for three different feed rate values. It turned out that the introduced changes significantly reduced both the axial cutting force (22–23%) and the height of burrs (10–22%) and caused the complete elimination of the presence of drilling caps. Additionally, a positive correlation between the cutting force and the burr size was found.

Sign in / Sign up

Export Citation Format

Share Document