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.

An Experiment-Based Investigation on Characteristic and Model of Milling Forces during End-Milling Aluminum Alloy

2014 ◽  
Vol 494-495 ◽  
pp. 602-605
Author(s):  
Zeng Hui An ◽  
Xiu Li Fu ◽  
Ya Nan Pan ◽  
Ai Jun Tang
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
End Milling ◽  
Influence Factors ◽  
Cutting Speed ◽  
Cutting Depth ◽  
Milling Forces

Cutting forces is one of the important physical phenomena in metal cutting process. It directly affects the surface quality of machining, tool life and cutting stability. The orthogonal experiments of cutting forces and influence factors with indexable and solid end mill were accomplished and the predictive model of milling force was established during high speed end milling 7050-T7451 aluminum alloy. The paper makes research mainly on the influence which the cutting speed, cutting depth and feed have on the cutting force. The experimental results of single factor showed that the cutting forces increase earlier and drop later with the increase of cutting speed, and the cutting speed of inflexion for 7050-T7451 is 1100m/min. As axial cutting depth, radial cutting depth and feed rate increase, the cutting force grows in different degree. The cutting force is particularly sensitive to axial cutting depth and slightly to the radial cutting depth.

scholarly journals Assessment of Cutting Profile of AISI 1095 by Using Infrared Radiation Approach

2018 ◽  
Vol 7 (3.18) ◽  
pp. 79
Author(s):  
Mohammad Ashaari Kiprawi ◽  
Abdullah Yassin ◽  
Syed Tarmizi Syed Shazali ◽  
M Shahidul Islam ◽  
Mohd Azrin Mohd Said
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Infrared Radiation ◽  
Flank Wear ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Machining Process ◽  
Depth Of Cut ◽  
Edge Temperature

This research paper determines the relationship between cutting edge temperature, depth of cut, cutting speed, cutting forces and flank wear. The cutting edge temperature is determined by using a pyrometer consists of Indium Arsenide (InAs) and Indium Antimonide (InSb) photocells to detect infrared radiation that are released from cutting tool’s edge and cutting forces is measured by using a dynamometer. The machining process experiment is done by end milling the outer surface of AISI 1095 carbon steel. The output signal from the photocell and dynamometer is processed and recorded in the digital oscilloscope. Based on the results, the cutting edge temperature and cutting force increases as the depth of cut increases. Meanwhile, increasing cutting speed resulting in cutting edge temperature increases but decreasing in cutting force due to thermal deformation. Also, existence of progressive flank wear at cutting tool causes an increment in cutting edge temperature and cutting force proportionally.  

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%.

Analysis of Cutting Forces and Machining Error in Ball End Milling of Cylindrical Surfaces

2011 ◽  
Vol 328-330 ◽  
pp. 560-564
Author(s):  
Ba Sheng Ouyang ◽  
Guo Xiang Lin ◽  
Yong Hui Tang
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Cutting Conditions ◽  
Machining Error ◽  
Machined Surface ◽  
Convex Surfaces ◽  
Machining Errors ◽  
End Mills ◽  
Tool Deflections ◽  
Cutting Modes

Cutting forces and machining error in contouring of concave and convex surfaces using helical ball end mills are theoretically investigated. The cutting forces are evaluated based on the theory of oblique cutting. The machining errors resulting from the tool deflections due to these forces are evaluated at various points of the machined surface. The influence of various cutting conditions and cutting modes on machining error is investigated and discussed.

Application of MCDM-based TOPSIS method for the selection of optimal process parameter in turning of pure titanium

2017 ◽  
Vol 24 (7) ◽  
pp. 2009-2021 ◽  
Author(s):  
Akhtar Khan ◽  
Kalipada Maity
Keyword(s):  
Decision Making ◽  
Cutting Force ◽  
Pure Titanium ◽  
Cutting Speed ◽  
Optimal Combination ◽  
Depth Of Cut ◽  
Topsis Method ◽  
Content Type ◽  
Cp Ti ◽  
Selection Of

Purpose The purpose of this paper is to explore a multi-criteria decision-making (MCDM) methodology to determine an optimal combination of process parameters that is capable of generating favorable dimensional accuracy and product quality during turning of commercially pure titanium (CP-Ti) grade 2. Design/methodology/approach The present paper recommends an optimal combination of cutting parameters with an aim to minimize the cutting force (Fc), surface roughness (Ra), machining temperature (Tm) and to maximize the material removal rate (MRR) after turning of CP-Ti grade 2. This was achieved by the simultaneous optimization of the aforesaid output characteristics (i.e. Fc, Ra, Tm, and MRR) using the MCDM-based TOPSIS method. Taguchi’s L9 orthogonal array was used for conducting the experiments. The output responses (cutting force: Fc, surface roughness: Ra, machining temperature: Tm and MRR) were integrated together and presented in terms of a single signal-to-noise ratio using the Taguchi method. Findings The results of the proposed methodology depict that the higher MRR with desirable surface quality and the lower cutting force and machining temperature were observed at a combination of cutting variables as follows: cutting speed of 105 m/min, feed rate of 0.12 mm/rev and depth of cut of 0.5 mm. The analysis of variance test was conducted to evaluate the significance level of process parameters. It is evident from the aforesaid test that the depth of cut was the most significant process parameter followed by cutting speed. Originality/value The selection of an optimal parametric combination during the machining operation is becoming more challenging as the decision maker has to consider a set of distinct quality characteristics simultaneously. This situation necessitates an efficient decision-making technique to be used during the machining operation. From the past literature, it is noticed that only a few works were reported on the multi-objective optimization of turning parameters using the TOPSIS method so far. Thus, the proposed methodology can help the decision maker and researchers to optimize the multi-objective turning problems effectively in combination with a desirable accuracy.

FRACTAL-BASED ANALYSIS OF THE VARIATIONS OF CUTTING FORCES ALONG DIFFERENT AXES IN END MILLING OPERATION

Fractals ◽  
2018 ◽  
Vol 26 (06) ◽  
pp. 1850089 ◽  
Author(s):  
HAMIDREZA NAMAZI ◽  
ALI AKHAVAN FARID ◽  
TECK SENG CHANG
Keyword(s):  
Fractal Dimension ◽  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Fractal Theory ◽  
Radial Force ◽  
Machining Conditions ◽  
Feed Force ◽  
Milling Operation ◽  
Force Signal

Analysis of cutting forces in machining operation is an important issue. The cutting force changes randomly in milling operation where it makes a signal by plotting over time span. An important type of analysis belongs to the study of how cutting forces change along different axes. Since cutting force has fractal characteristics, in this paper for the first time we analyze the variations of complexity of cutting force signal along different axes using fractal theory. For this purpose, we consider two cutting depths and do milling operation in dry and wet machining conditions. The obtained cutting force time series was analyzed by computing the fractal dimension. The result showed that in both wet and dry machining conditions, the feed force (along [Formula: see text]-axis) has greater fractal dimension than radial force (along [Formula: see text]-axis). In addition, the radial force (along [Formula: see text]-axis) has greater fractal dimension than thrust force (along [Formula: see text]-axis). The method of analysis that was used in this research can be applied to other machining operations to study the variations of fractal structure of cutting force signal along different axes.

Ultrasonic Cutting of Switchgrass and Miscanthus Stems

2018 ◽  
Vol 34 (2) ◽  
pp. 343-353
Author(s):  
A. Bulent Koc Koc ◽  
Bo Liu
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Frequency ◽  
Cutting Speed ◽  
Particle Size Reduction ◽  
Element Analysis ◽  
Cutting Energy ◽  
High Frequency Vibrations ◽  
Ultrasound Assisted ◽  
Ultrasonic Cutting

Abstract. Ultrasound-assisted cutting has been used to cut materials with high precision, improved quality and reduced cutting forces. The research objective was to investigate the effects of high-frequency vibrations on the cutting force and cutting energy of switchgrass and miscanthus stems. Laboratory experiments were conducted on individual biomass stems at cutting speeds between 3 and 400 mm/s. An experimental cutting system with an ultrasound generator, an ultrasonic blade, a load cell, and a data acquisition system was developed. The custom designed blade was 5-cm wide and vibrated at 19.551 kHz with 2.8 µm tip vibration amplitude. There were significant measured differences in the cutting forces and cutting energies between conventional cutting and ultrasonic cutting of switchgrass and miscanthus stems (p < 0.05). These results suggest that the use of high-frequency vibrations reduce cutting force and cutting energy of both switchgrass and miscanthus stems. Ultrasound-assisted cutting reduced the cutting energy of switchgrass by 66.85% at 100 mm/s and miscanthus by 80.58% at 30 mm/s. However, ultrasonic cutting did not have a significant effect on the cutting force and cutting energy when the cutting speed was equal to or greater than the blade tip vibration speed. The results of this research should be useful for adapting the ultrasonic technology in biomass harvesting, particle size reduction, and processing equipment. Keywords: Biomass, Blades, Energy, Finite element analysis, Miscanthus, Switchgrass, Ultrasonics.

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

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.

Analytical Convolution Model of Cutting Forces in 3-D Ball End Milling

2001 ◽  
Author(s):  
Richard Y. Chiou ◽  
Bing Zhao
Keyword(s):  
Cutting Force ◽  
Frequency Domain ◽  
Cutting Forces ◽  
End Milling ◽  
Force Model ◽  
Three Dimensional Model ◽  
Calculation Algorithm ◽  
Ball End Milling ◽  
Convolution Model ◽  
Force Calculation

Abstract This paper presents an analytical convolution model of dynamic cutting forces in ball end milling of 3-D plane surfaces. The model takes into account the instantaneous slope on a sculptured surface to establish the chip geometry in cutting force calculation algorithm. A three-dimensional model of cutting forces in ball end milling is presented in terms of material properties, cutting parameters, machining configuration, and tool/work geometry. Based on the relationship of the local cutting force, chip load and engaged boundary, the total cutting force model is established via the angle domain convolution integration of the local forces in the feed, cross feed, axial direction, and inclination angle. The convolution integral leads to a periodic function of cutting forces in the angle domain and an explicit expression of the dynamic cutting force components in the frequency domain. Following the theoretical analysis, experimental study is discussed to illustrate the implementation procedure for force identification, and frequency domain data are presented to verify the analytical results.

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