Application of higher polynomial with variable coefficients to investigation of tool wear and fracture-fusion model in monitoring the cutting processes of turning and end-milling

1993 ◽  
Author(s):  
Zhen-Bi Luo ◽  
Yu Quan ◽  
Zheng Li ◽  
Anne J. Wang
Keyword(s):  
Tool Wear ◽  
End Milling ◽  
Variable Coefficients ◽  
Fusion Model ◽  
Cutting Processes

Sensor Fusion for Condition Monitoring System of End Milling Operations

2010 ◽  
Vol 450 ◽  
pp. 267-270 ◽  
Author(s):  
Jabbar Abbas ◽  
Amin Al-Habaibeh ◽  
Dai Zhong Su
Keyword(s):  
Signal Processing ◽  
Tool Wear ◽  
Sensor Fusion ◽  
End Milling ◽  
Fusion Model ◽  
Suggested Approach ◽  
Milling Operations ◽  
Wide Range ◽  
Characteristic Features ◽  
Condition Monitoring System

This paper describes the utilisation of multi sensor fusion model using force, vibration, acoustic emission, strain and sound sensors for monitoring tool wear in end milling operations. The paper applies the ASPS approach (Automated Sensor and Signal Processing Selection) method for signal processing and sensor selection [1]. The sensory signals were processed using different signal processing methods to create a wide range of Sensory Characteristic Features (SCFs). The sensitivity of these SCFs to tool wear is investigated. The results indicate that the sensor fusion system is capable of detecting machining faults in comparison to a single sensor using the suggested approach.

Process Design and Optimization of end Milling Parameters of Al 7075 Metal Matrix Composite

2021 ◽  
pp. 929-937
Author(s):  
D. S. Sai Ravi Kiran ◽  
Alavilli Sai Apparao ◽  
Vempala GowriSankar ◽  
Shaik Faheem ◽  
Sheik Abdul Mateen ◽  
...  
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Metal Matrix ◽  
Material Removal ◽  
Hybrid Composites ◽  
End Milling ◽  
Removal Rate ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Weight Percentage

This paper investigates the machinability characteristics of end milling operation to yield minimum tool wear with the maximum material removal rate using RSM. Twenty-seven experimental runs based on Box-Behnken Design of Response Surface Methodology (RSM) were performed by varying the parameters of spindle speed, feed and depth of cut in different weight percentage of reinforcements such as Silicon Carbide (SiC-5%, 10%,15%) and Alumina (Al2O3-5%) in alluminium 7075 metal matrix. Grey relational analysis was used to solve the multi-response optimization problem by changing the weightages for different responses as per the process requirements of quality or productivity. Optimal parameter settings obtained were verified through confirmatory experiments. Analysis of variance was performed to obtain the contribution of each parameter on the machinability characteristics. The result shows that spindle speed and weight percentage of SiC are the most significant factors which affect the machinability characteristics of hybrid composites. An appropriate selection of the input parameters such as spindle speed of 1000 rpm, feed of 0.02 mm/rev, depth of cut of 1 mm and 5% of SiC produce best tool wear outcome and a spindle speed of 1838 rpm, feed of 0.04 mm/rev, depth of cut of 1.81 mm and 6.81 % of SiC for material removal rate.

Investigation on the Tool Wear Model and Equivalent Tool Life in End Milling Titanium Alloy Ti6Al4V

2018 ◽  
Author(s):  
Kai Guo ◽  
Bin Yang ◽  
Jie Sun ◽  
Vinothkumar Sivalingam
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Carbide Tool ◽  
Wear Model ◽  
Wear Process ◽  
Coated Carbide Tool ◽  
Coated Carbide

Titanium alloys are widely utilized in aerospace thanks to their excellent combination of high-specific strength, fracture, corrosion resistance characteristics, etc. However, titanium alloys are difficult-to-machine materials. Tool wear is thus of great importance to understand and quantitatively predict tool life. In this study, the wear of coated carbide tool in milling Ti-6Al-4V alloy was assessed by characterization of the worn tool cutting edge. Furthermore, a tool wear model for end milling cutter is established with considering the joint effect of cutting speed and feed rate for characterizing tool wear process and predicting tool wear. Based on the proposed tool wear model equivalent tool life is put forward to evaluate cutting tool life under different cutting conditions. The modelling process of tool wear is given and discussed according to the specific conditions. Experimental work and validation are performed for coated carbide tool milling Ti-6Al-4V alloy.

scholarly journals Delamination Study in Edge Trimming of Basalt Fiber Reinforced Plastics (BFRP)

Materials ◽  
2018 ◽  
Vol 11 (8) ◽  
pp. 1418 ◽  
Author(s):  
Maria Navarro-Mas ◽  
Juan García-Manrique ◽  
Maria Meseguer ◽  
Isabel Ordeig ◽  
Ana Sánchez
Keyword(s):  
Tool Wear ◽  
Volume Fraction ◽  
End Milling ◽  
Basalt Fiber ◽  
Depth Of Cut ◽  
Fiber Reinforced ◽  
Fiber Volume ◽  
Reinforced Plastics ◽  
Fiber Reinforced Plastics ◽  
Edge Trimming

Although there are many machining studies of carbon and glass fiber reinforced plastics, delamination and tool wear of basalt fiber reinforced plastics (BFRP) in edge trimming has not yet studied. This paper presents an end milling study of BFRP fabricated by resin transfer molding (RTM), to evaluate delamination types at the top layer of the machined edge with different cutting conditions (cutting speed, feed rate and depth of cut) and fiber volume fraction (40% and 60%). This work quantifies delamination types, using a parameter Sd/L, that evaluates the delamination area (Sd) and the length (L), taking into account tool position in the yarn and movement of yarns during RTM process, which show the random nature of delamination. Delamination was present in all materials with 60% of fiber volume. High values of tool wear did not permit to machine the material due to an excessive delamination. Type II delamination was the most usual delamination type and depth of cut has influence on this type of delamination.

scholarly journals UNDERSTANDING TEMPERATURE EFFECTS ON FRICTION AT TOOL – CFRP WORKPIECE INTERFACE USING OPEN-LOOP FRICTION TESTING

2021 ◽  
Vol 2021 (3) ◽  
pp. 4605-4611
Author(s):  
S. Ashworth ◽  
◽  
K. Kerrigan ◽  
Keyword(s):  
Tool Wear ◽  
Thermal Effects ◽  
Temperature Effects ◽  
Open Loop ◽  
Friction Testing ◽  
Reinforced Polymer ◽  
Carbon Fibre Reinforced Polymer ◽  
Fibre Reinforced Polymer ◽  
Cutting Processes ◽  
Coated Carbide

Cutting processes of carbon fibre reinforced polymer (CFRP) material generate significant energy in the form of heat which can be detrimental to final surface and sub-surface quality. By artificially changing the temperature of the workpiece to simulate cutting temperatures, thermal effects on friction metrics can be understood. Feed rate and CFRP pre-heating for macro and nanoscale open loop pin on plate friction testing has been completed for two aerospace grade CFRP materials with steel, carbide and coated carbide pins to give an insight to fundamental tool wear that occurs in CFRP machining.

Influence of cutting speed on cutting force, flank temperature, and tool wear in end milling of Ti-6Al-4V alloy

2013 ◽  
Vol 70 (9-12) ◽  
pp. 1835-1845 ◽  
Author(s):  
Junzhan Hou ◽  
Wei Zhou ◽  
Hongjian Duan ◽  
Guang Yang ◽  
Hongwei Xu ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed

Supervision of Tool Wear and Surface Quality During End Milling Operations

1994 ◽  
Vol 27 (4) ◽  
pp. 507-512 ◽  
Author(s):  
H. Konrad ◽  
R. Isermann ◽  
H.U. Oette
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
End Milling ◽  
Milling Operations
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