EXPERIMENTAL INVESTIGATION OF QUALITY METRICS FORMATION PROCESS DURING PLASTIC MILLING

2016 ◽  
Vol 2016 (3) ◽  
pp. 129-136 ◽  
Author(s):  
Павел Черданцев ◽  
Pavel Cherdantsev ◽  
Андрей Марков ◽  
Andrey Markov ◽  
Софья Катаева ◽  
...  
Keyword(s):  
Composite Materials ◽  
Tool Wear ◽  
Cutting Speed ◽  
Experimental Investigations ◽  
Geometrical Parameters ◽  
Original Design ◽  
Transverse Fiber ◽  
Fiber Winding ◽  
Estimate Of Parameter ◽  
Cutting Modes

Composite materials are widely used in mechanical engineering, but at edge cutting machining, in particular, during milling these materials a number of peculiarities arise which must be taken into account at the definition of cutting modes and design-geometrical parameters of cutters. Besides, new composite materials machining does not allow using effectively the recommendations developed earlier. In such a way, to solve such a problem it is necessary to carry out experimental investigations on the analysis of the influence of milling mode characteristics and design-geometrical of a tool upon values of roughness of a surface processed and tool wear. As a cutter for investigations there were taken hardmetal endmilling cutters of TC-8 (tungstencobalt) type, the experimental samples – pipes made of composite material with oblique longi-tudinal-transverse fiber winding (OLTFW). As varied parameters were adopted cutting modes: cutting speed V, m/min, feed S, mm/tooth and milling depth t, mm. During the experiments were controlled the following parameters: tool wear Δ, mkm, roughness of the surface Ra, mkm and a depth of a faulty layer h, mkm. To carry out the experiments there was offered an original design of an assembly milling cutter which allows defining in an experimental way optimum geo-metrical parameters of a tools to achieve output milling parameters specified. On the basis of experiments data there are obtained dependences allowing the estimate of parameter modes influence upon the period of cutter duration at the same time a temperature is affected mostly by a milling depth and a feed on a tooth affects the wear of an end flank.

Analysis and Simulation of Cutting Technologies for Lightweight Frame Components

2006 ◽  
Vol 10 ◽  
pp. 53-64 ◽  
Author(s):  
Klaus Weinert ◽  
Niels Hammer ◽  
Jens Rautenberg
Keyword(s):  
Composite Materials ◽  
Tool Wear ◽  
Matrix Material ◽  
Experimental Investigations ◽  
Mechanical Loads ◽  
Milling Operations ◽  
Quality Aspects ◽  
Drilling Operations ◽  
Thin Walled ◽  
Conventional Drilling

Innovative composite extrusions consisting of an aluminium matrix material with steel fibres for reinforced lightweight constructions require adapted cutting technologies. Due to the resulting tool wear when machining such composite materials, new tools and processes have to be developed. The following article describes experimental investigations concerning conventional drilling operations in comparison to helix milling operations for the manufacturing of holes in these materials. Therefore especially wear and quality aspects are discussed. Furthermore a flexible cutting process for thin walled lightweight frame connector elements to combine profiles is described. To obtain detailed process knowledge also FEA-Simulations of the thermo-mechanical loads affecting the workpiece during the process are performed.

scholarly journals Recent advances in twist drill design for composite machining: A critical review

2016 ◽  
Vol 231 (14) ◽  
pp. 2527-2542 ◽  
Author(s):  
Sikiru Oluwarotimi Ismail ◽  
Hom Nath Dhakal ◽  
Eric Dimla ◽  
Ivan Popov
Keyword(s):  
Composite Materials ◽  
Tool Wear ◽  
Critical Review ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Clear Understanding ◽  
Twist Drill ◽  
Twist Drills ◽  
Composite Drilling ◽  
Drill Design

In the field of composite technology, inefficient and poor designs of twist drills contribute immensely to the challenges facing drilling of composite materials. An attempt to report some of the drill design methods and their inherent challenges confronting composite machining necessitates the writing of this article. A critical review has been conducted to offer a clear understanding of the current advances in the field of mechanical drilling of composite materials, focusing on geometry, material and parametric tool designs. The inter-dependable effects of thrust force, cutting speed, feed rate, cutting force and torque on drill design are similarly reviewed. This article also reveals other associated issues facing composite drilling including delamination, surface roughness, rapid tool wear and drill breakage. Well-designed drill geometry and good knowledge of drilling parameters afford the producers of polycrystalline diamond, carbide and high-speed steel tooling materials better opportunity of developing a drill that will minimise delamination of the reinforced composites and tool wear and produce a high-quality surface. Twist drill manufacturers and users will benefit from this article as they seek to have well-designed and improved drills.

Experimental Investigations on Surface Roughness, Cutting Forces and Tool Wear in Turning of Super Duplex Stainless Steel With Coated Carbide Inserts

2017 ◽  
Author(s):  
Shirish Kadam ◽  
Rohit Khake ◽  
Sadaiah Mudigonda
Keyword(s):  
Stainless Steel ◽  
Tool Wear ◽  
Duplex Stainless Steel ◽  
Cutting Speed ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Super Duplex Stainless Steel ◽  
Coated Carbide ◽  
Carbide Inserts

This paper addresses experimental investigations of turning Super Duplex Stainless Steel (DSS) with uncoated and Physical Vapor Deposition PVD coated carbide inserts under dry cutting condition. The parametric influence of cutting speed, feed and depth of cut on the surface finish and machinability aspects such as cutting force and tool wear are studied and conclusions are drawn. The turning parameters considered are cutting speed of 60–360 m/min, feed of 0.05–0.35 mm/rev and depth of cut of 0.5–2 mm. Tool wear was analysed by using an optical microscope and scanning electron microscope. The study includes identification of tool wear mechanism occurring on the flank face. The characterization of the coating was made by Calo test for measurement of coating thickness and nanoindentation for hardness. Comparison of performance of PVD coatings TiAlSiN (3.3μm), AlTiN (3 μm) and AlTiN (7 μm) have been made in terms of tool life. The coatings were produced on P-grade tungsten carbide inserts by using High Power Impulse Magnetron Sputtering (HiPIMS) technology. The findings of the study also provide the economic solution in case of dry turning of super DSS.

Machinability of Fiber-Reinforced Thermoplastics in Drilling

1993 ◽  
Vol 115 (1) ◽  
pp. 146-149 ◽  
Author(s):  
H. Hocheng ◽  
H. Y. Puw
Keyword(s):  
Composite Materials ◽  
Carbon Fiber ◽  
Tool Wear ◽  
High Speed ◽  
Cutting Speed ◽  
High Speed Steel ◽  
Fiber Reinforced ◽  
Heat Accumulation ◽  
Edge Quality ◽  
Carbon Fiber Reinforced

Polymer-based composite materials are used in a variety of industry. Recently, thermoplastic polymer suitable for the resinous matrix in carbon fiber-reinforced composites has been introduced for lower material and processing costs, improved damage tolerance and higher moisture resistance. The successful use of this material requires sophisticated production technology, however little reference of machining of thermoplastics composites can be found. The existing published results are almost exclusively for epoxy-based composite materials showing difficulty in avoiding poor finish, serious tool wear and delamination at hole entrance and exit due to the brittle material response to machining. Thermoplastics-based composite materials possesses better machinability. The current work reveals the machinability of an example of carbon fiber-reinforced ABS (Acrylonitrile Butadiene Styrene) in drilling compared to representative metals and thermoset-based composites. The observation of chips reveals that considerable plastic deformation is involved. Compared to the chip formation of thermoset plastics, it contributes to the improved edge quality in drilling. The edge quality is generally fine except in the case of concentrated heat accumulation at tool lips, which is generated by high cutting speed and low feed rate. Plastics tend to be extruded out of the edge rather than neatly cut. The average surface roughness along hole walls in commonly below one micron for all sets of cutting conditions in the experiment, values between 0.3 and 0.6 microns are typical. The high speed steel drill presents only minor tool wear during the tests. Based on these results, one concludes that the carbon fiber-reinforced ABS demonstrates good machinability in drilling.

Optimisation of milling parameters with multi-performance characteristic on Al/SiC metal matrix composite using grey-fuzzy logic algorithm

2018 ◽  
Vol 14 (2) ◽  
pp. 284-305 ◽  
Author(s):  
Rajeswari S. ◽  
Sivasakthivel P.S.
Keyword(s):  
Surface Roughness ◽  
Fuzzy Logic ◽  
Tool Wear ◽  
Cutting Speed ◽  
Helix Angle ◽  
Rake Angle ◽  
Depth Of Cut ◽  
Geometrical Parameters ◽  
Content Type ◽  
Minimum Surface

Purpose The purpose of this paper is to determine the optimum level of geometrical parameters such as helix angle, nose radius, rake angle and machining parameters such as cutting speed, feed rate and depth of cut to arrive minimum surface roughness and tool wear during end milling of Al 356/SiC metal matrix composites (MMCs) using high speed steel end mill cutter. Design/methodology/approach L27 Taguchi orthogonal design with six factors and three levels is employed for conducting experiments. Analysis of variance (ANOVA) is carried out using Minitab16 software to find the influence of each input parameter on output performance measure. Grey-fuzzy logic multi optimisation algorithm is used to find the optimum level of the input parameters for minimum surface roughness and tool wear simultaneously. Findings It is found that optimal combination of helix angle 40°, nose radius 0.8 mm, rake angle 12°, cutting speed 90 m/min, feed rate 0.04 mm/rev and depth of cut 1.5 mm have generated minimum surface roughness of 0.4063 µm and tool wear of 0.0375 mm. From ANOVA analysis, it is found that cutting speed influence is more on output performance followed by helix angle and rake angle compared with other machining and geometrical parameters. Originality/value The influence of tool geometry during end milling of MMC using Grey-fuzzy logic algorithm has not been explored previously.

Optimization of Cutting Parameters in Milling Process Using Genetic Algorithm and ANOVA (March 2020)

2020 ◽  
Vol 38 (10A) ◽  
pp. 1489-1503
Author(s):  
Marwa Q. Ibraheem
Keyword(s):  
Genetic Algorithm ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Optimal Value ◽  
Optimization Of Cutting Parameters

In this present work use a genetic algorithm for the selection of cutting conditions in milling operation such as cutting speed, feed and depth of cut to investigate the optimal value and the effects of it on the material removal rate and tool wear. The material selected for this work was Ti-6Al-4V Alloy using H13A carbide as a cutting tool. Two objective functions have been adopted gives minimum tool wear and maximum material removal rate that is simultaneously optimized. Finally, it does conclude from the results that the optimal value of cutting speed is (1992.601m/min), depth of cut is (1.55mm) and feed is (148.203mm/rev) for the present work.

INVESTIGATION OF DEPENDENCE IMPACT OF TOOL GEOMETRICAL PARAMETERS AND CUTTING SPEED UPON SHAPING EFFORT AT HELICAL GROOVE CUTTING ON INTERNAL SURFACE OF CYLINDRICAL SHELL

2020 ◽  
Vol 2020 (10) ◽  
pp. 22-28
Author(s):  
Vadim Kuc ◽  
Dmitriy Gridin
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cylindrical Shell ◽  
Contact Interaction ◽  
Cutting Speed ◽  
Internal Surface ◽  
Geometrical Parameters ◽  
Software Complex ◽  
Helical Groove ◽  
Groove Cutting

The work purpose was the investigation of dependence impact of tool geometrical parameters upon shaping effort during internal groove cutting. As a realization for the fulfillment of the helical groove processing investigation there was used a software complex based on a finite element method and a computer mathematic system. As a result of the investigations carried out there was obtained a regression equation manifesting the dependence of factors impact upon axial force falling on one tooth of the tool in the set scale of factor parameters. The scientific novelty consists in that in the paper there is considered a new method for helical groove cutting in which a shaping motion is carried out at the expense of the contact interaction of a tool and a billet performing free cutting. The investigation results obtained allowed determining the number of teeth operating simultaneously, that can be used further at cutting mode setting, and also as recommendations during designing tool design.

scholarly journals Influence of Tool Wear on Form Deviations in Dry Machining of UNS A97075 Alloy

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 958
Author(s):  
Francisco Javier Trujillo Vilches ◽  
Sergio Martín Béjar ◽  
Carolina Bermudo Gamboa ◽  
Manuel Herrera Fernández ◽  
Lorenzo Sevilla Hurtado
Keyword(s):  
Tool Wear ◽  
General Trend ◽  
Cutting Speed ◽  
Main Tool ◽  
Cutting Parameters ◽  
Adhesion Wear ◽  
Tool Wear Mechanisms ◽  
Tool Wear Mechanism ◽  
High Feed ◽  
Dry Conditions

Geometrical tolerances play a very important role in the functionality and assembly of parts made of light alloys for aeronautical applications. These parts are frequently machined in dry conditions. Under these conditions, the tool wear becomes one of the most important variables that influence geometrical tolerances. In this work, the influence of tool wear on roundness, straightness and cylindricity of dry-turned UNS A97075 alloy has been analyzed. The tool wear and form deviations evolution as a function of the cutting parameters and the cutting time has been assessed. In addition, the predominant tool wear mechanisms have been checked. The experimental results revealed that the indirect adhesion wear (BUL and BUE) was the main tool-wear mechanism, with the feed being the most influential cutting parameter. The combination of high feed and low cutting speed values resulted in the highest tool wear. The analyzed form deviations showed a general trend to increase with both cutting parameters. The tool wear and the form deviations tend to increase with the cutting time only within the intermediate range of feed tested. As the main novelty, a relationship between the cutting parameters, the cutting time (and, indirectly, the tool wear) and the analyzed form deviations has been found.

The effect of nanoparticle additive on surface milling in glass fiber reinforced composite structures

2021 ◽  
pp. 096739112110141
Author(s):  
Ferhat Ceritbinmez ◽  
Ahmet Yapici ◽  
Erdoğan Kanca
Keyword(s):  
Composite Materials ◽  
Glass Fiber ◽  
Composite Structures ◽  
Fiber Composite ◽  
Cutting Speed ◽  
Fiber Reinforced ◽  
Fiber Reinforced Composite ◽  
Reinforced Composite ◽  
Glass Fiber Reinforced ◽  
Composite Layers

In this study, the effect of adding nanosize additive to glass fiber reinforced composite plates on mechanical properties and surface milling was investigated. In the light of the investigations, with the addition of MWCNTs additive in the composite production, the strength of the material has been changed and the more durable composite materials have been obtained. Slots were opened with different cutting speed and feed rate parameters to the composite layers. Surface roughness of the composite layers and slot size were examined and also abrasions of cutting tools used in cutting process were determined. It was observed that the addition of nanoparticles to the laminated glass fiber composite materials played an effective role in the strength of the material and caused cutting tool wear.

scholarly journals Machining of Titanium Metal Matrix Composites: Progress Overview

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 5011
Author(s):  
Cécile Escaich ◽  
Zhongde Shi ◽  
Luc Baron ◽  
Marek Balazinski
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanisms ◽  
Metal Matrix ◽  
Dust Emission ◽  
Cutting Speed ◽  
Matrix Composites ◽  
Titanium Metal ◽  
Machining Processes ◽  
Tool Wear Mechanisms

The TiC particles in titanium metal matrix composites (TiMMCs) make them difficult to machine. As a specific MMC, it is legitimate to wonder if the cutting mechanisms of TiMMCs are the same as or similar to those of MMCs. For this purpose, the tool wear mechanisms for turning, milling, and grinding are reviewed in this paper and compared with those for other MMCs. In addition, the chip formation and morphology, the material removal mechanism and surface quality are discussed for the different machining processes and examined thoroughly. Comparisons of the machining mechanisms between the TiMMCs and MMCs indicate that the findings for other MMCs should not be taken for granted for TiMMCs for the machining processes reviewed. The increase in cutting speed leads to a decrease in roughness value during grinding and an increase of the tool life during turning. Unconventional machining such as laser-assisted turning is effective to increase tool life. Under certain conditions, a “wear shield” was observed during the early stages of tool wear during turning, thereby increasing tool life considerably. The studies carried out on milling showed that the cutting parameters affecting surface roughness and tool wear are dependent on the tool material. The high temperatures and high shears that occur during machining lead to microstructural changes in the workpiece during grinding, and in the chips during turning. The adiabatic shear band (ASB) of the chips is the seat of the sub-grains’ formation. Finally, the cutting speed and lubrication influenced dust emission during turning but more studies are needed to validate this finding. For the milling or grinding, there are major areas to be considered for thoroughly understanding the machining behavior of TiMMCs (tool wear mechanisms, chip formation, dust emission, etc.).

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