scholarly journals An Experimental Study on Milling Titanium Alloy with a Revolving Cycloid Milling Cutter

2020 ◽  
Vol 10 (4) ◽  
pp. 1423
Author(s):  
Guangyue Wang ◽  
Xianli Liu ◽  
Tao Chen ◽  
Weijie Gao
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Quality ◽  
Axial Force ◽  
End Milling ◽  
Tangential Force ◽  
Helix Angle ◽  
Rake Angle ◽  
Milling Cutter ◽  
Ball End Milling

In this paper, a revolving cycloid milling cutter was designed with a larger effective cutting helix angle and rake angle than a ball end milling cutter of the same diameter. This new type of milling cutter can solve the problems of low machining efficiency, severe tool wear, and low surface quality in titanium alloy processing. A comparison of the cutting performance of titanium alloys processed by the revolving cycloid milling cutter and the ball end milling cutter was carried out to obtain the variation laws of the cutting force and the processing surface quality under different tool wear conditions. The result shows that the wear zone of the revolving cycloid milling cutter is shallow and wide compared to that of the ball end milling cutter. As the wear speeds up, the spoon-shaped wear gathering zone found in the ball end milling cutter does not happen with the revolving cycloid milling cutter. The revolving cycloid milling cutter can significantly lower the axial force, the tangential force, and the ratio of the axial force to the tangential force with a stable cutting process.

scholarly journals Study on the Design and Cutting Performance of a Revolving Cycloid Milling Cutter

2019 ◽  
Vol 9 (14) ◽  
pp. 2915 ◽  
Author(s):  
Guangyue Wang ◽  
Xianli Liu ◽  
Weijie Gao ◽  
Bingxin Yan ◽  
Tao Chen
Keyword(s):  
Titanium Alloy ◽  
End Milling ◽  
Tangential Force ◽  
Boundary Curve ◽  
Cutting Performance ◽  
Machining Process ◽  
Rake Face ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Five Axis

Problems such as low machining efficiency, severe tool wear and difficulty in safeguarding surface quality always exist in the machining process of titanium alloy with ball-end milling cutters. To address these issues, the design and manufacture of a revolving cycloid milling cutter for titanium alloy processing were studied in this paper. Firstly, the mathematical model of the revolving cycloid milling cutter contour surface was established. The parametric equation of an orthogonal helix cutting edge curve of a revolving cycloid milling cutter is presented. Then, the bottom boundary curve of the rake face is introduced. The five-axis grinding trajectory equation of revolving cycloid milling cutter rake face was derived based on the edge curve equation and coordinate transformation. Next, fabricating the revolving cycloid milling cutter and detecting the grinding accuracy of tool profile and geometric angle were performed. At last, a contrast test regarding the performance of the revolving cycloid milling cutter and the ball-end milling cutter in cutting titanium alloy TC11 was carried out. According to the test results, in comparison to the ball-end milling cutter, the revolving cycloid milling cutter had a smaller ratio of the axial force to the tangential force. Moreover, its flank face wore more slowly and evenly. As a result, a good surface processing quality can be maintained even under larger wear conditions, demonstrating an outstanding cutting performance.

An Investigation of Wear of Ball End Milling Cutter for High-Speed Milling of Hardened Cr12MoV Steel

2014 ◽  
Vol 800-801 ◽  
pp. 475-478 ◽  
Author(s):  
Cai Xu Yue ◽  
Hui Ze Feng ◽  
Jing Ma ◽  
Zhao Nan Zhong ◽  
Fei Liu
Keyword(s):  
Tool Life ◽  
High Speed ◽  
End Milling ◽  
Helix Angle ◽  
Rake Angle ◽  
Milling Cutter ◽  
High Speed Milling ◽  
Ball End Milling ◽  
Edge Stiffness

The high-speed milling experiments on hardened Cr12MoV steel were carried out with ball end milling cutter of different edge parameters. The influences of helix angle and rake angle on tool life and surface roughness were focused on. Meanwhile, the impacts of edge parameters on cutting edge stiffness and flank wear were analyzed on the condition of high-speed milling. It carried out that smaller helix angle and negative rake angle selected during high speed milling can guarantee quality of surface manufactured as well as longer tool life.

Investigation on Chip Morphology and Surface Quality in High-Speed Ball-End Milling of Inconel 718

2010 ◽  
Vol 443 ◽  
pp. 353-358 ◽  
Author(s):  
Harshad A. Sonawane ◽  
Suhas S. Joshi
Keyword(s):  
Surface Quality ◽  
Inconel 718 ◽  
High Speed ◽  
End Milling ◽  
Chip Morphology ◽  
Helix Angle ◽  
Processing Parameters ◽  
Milling Process ◽  
Machining Parameters ◽  
Ball End Milling

The ball end milling process, commonly used for generating complex shapes, involves continuous variation in the uncut chip dimensions, which depends on the cutter geometry and the machining parameters. The proposed analytical model evaluates the undeformed and the deformed chip dimensions including chip length, width and thickness. The undeformed and deformed chip dimensions, is a function of cutter rotation angle, instantaneous cutter radius, helix angle, and other processing parameters. The surface quality, in the form of surface roughness, during high-speed ball end milling of Inconel 718 is also analysed in this paper.

Effect of Tool Wear on Surface Qualities in Milling of TC4

2016 ◽  
Vol 836-837 ◽  
pp. 132-138 ◽  
Author(s):  
Shu Cai Yang ◽  
Xiao Yang Cui ◽  
Yu Hua Zhang ◽  
Zhi Wei Wang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Quality ◽  
End Milling ◽  
Great Influence ◽  
Chip Morphology ◽  
Milling Process ◽  
Serrated Chip ◽  
Quality Surface

Tool wear is easy occurred in titanium alloy milling process which will affect the surface quality. Surface roughness and surface morphology as an important index to describe and evaluate the surface quality has a great influence on service performance. Therefore, the study on the effect of tool wear on surface qualities is important to improve the surface integrity of titanium alloy parts. Cutting radius of ball-end milling cutter is solved to analyze the effect of tool wear on the cutting radius. The tool wear and the surface qualities of TC4 are achieved through wear experiment. And then the influence law of tool wear on surface qualities and chip morphology are analyzed. The results show that surface roughness value decrease firstly and then increases and that chip morphology with flank wear increase from the unit chip to the serrated chip.

scholarly journals Wear optimization of titanium alloy cutter milled with microtextured ball-end milling cutter

2020 ◽  
Vol 12 (1) ◽  
pp. 168781401989210
Author(s):  
Yuhua Zhang ◽  
Hongzhi Ji
Keyword(s):  
Tool Wear ◽  
End Milling ◽  
Optimal Solution ◽  
Optimization Method ◽  
Multi Objective Optimization ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Orthogonal Experiments ◽  
Texture Parameters ◽  
Optimal Solution Set

Aimed at solving the problems of tool wear and poor surface quality in milling a Ti alloy with a ball-end milling cutter, a method of applying a microtexture to a tool rake face to reduce tool wear is proposed in this article. By comparing the wear morphology of microtextured tools with that of nontextured tools after milling with the same stroke, the antifriction and antiwear mechanism of the micropit texture and the failure mode of the ball-end milling cutter are analyzed. The results of a simulation and orthogonal experiments reveal that with the increase of the micropit parameters, the wear value of the rake and rear faces first decreases and then increases. The effects of the micropit parameters on the wear value of the ball-end milling cutter decrease in the following order: distance from edge > diameter > spacing > depth. Finally, by using a multi-objective optimization method, the optimal solution set of the texture parameters of micropits is obtained by evaluating the wear values of the rake and rear faces of the ball-end milling cutters: 46 μm < diameter < 50 μm, 23 μm < depth < 26 μm, 109 μm < spacing < 112 μm, and 85 μm < distance from edge < 89 μm.

scholarly journals Models of the relationship among geometric parameters and anti-friction mechanism of micro-texture ball-end milling cutter

2018 ◽  
Vol 10 (6) ◽  
pp. 168781401878147 ◽  
Author(s):  
Xianli Liu ◽  
Xin Tong ◽  
Shucai Yang ◽  
Chunsheng He ◽  
Xiao Liu
Keyword(s):  
Titanium Alloy ◽  
End Milling ◽  
Geometric Parameters ◽  
Friction Mechanism ◽  
Milling Cutter ◽  
Characteristic Model ◽  
Ball End Milling ◽  
Texture Parameters ◽  
Efficient Processing ◽  
The Relationship

Researches on the effect of the micro-texture on the cutting performance and the life of cutters are mostly aimed at turning cutters, but there are few researches on the ball-end milling cutter. On the basis geometry of the micro-texture, the distribution and the relationship among the geometric parameters of micro-pits are studied. A mechanical characteristic model of machining titanium alloy with the micro-texture ball-end milling cutter is established. Optimal parameters of the micro-texture are determined by the simulation. By the test of machining the titanium alloy with the micro-texture ball-end milling cutter, anti-friction properties, the influence laws of the micro-texture diameter on forces, and area occupancy on the tool wear are studied. This article provides a theoretical reference for determining the location of the micro-texture on ball-end milling cutter and selecting texture parameters reasonably. The anti-friction mechanism of the micro-texture is revealed by the theory, which provides a theoretical basis for the efficient processing of titanium alloy.

Investigation on the stress field of milling titanium alloys with micro-textured ball-end milling cutter

2019 ◽  
Vol 233 (11) ◽  
pp. 2160-2172 ◽  
Author(s):  
Shucai Yang ◽  
Chunsheng He ◽  
Minli Zheng
Keyword(s):  
Titanium Alloy ◽  
Stress Field ◽  
Density Function ◽  
End Milling ◽  
Equivalent Stress ◽  
Force Density ◽  
Stress And Strain ◽  
Milling Force ◽  
Milling Cutter ◽  
Ball End Milling

In the milling of titanium alloy, the distribution of milling force and its related law of change seriously affect the physical properties of workpiece materials, the stress distribution on a cutter’s rake face and the interaction between the workpiece, the cutter and the chip. This article reports on a study of the stress field distribution under the conditions of anti-friction and anti-wear when cutting titanium alloy with a micro-textured ball-end milling cutter. Milling test data were used to establish empirical models of milling force and the contact area between the cutter and the chip. Based on this, the force density function of the cutter coordinate system was obtained and the equivalent stress and displacement of the cutter were simulated and analyzed. This in turn provided the means to acquire the instantaneous stress and strain relating to the cutter at any time. Analysis of the simulation results shows that the position in which the stress and strain are concentrated on the cutter is consistent with actual processing. This confirms the accuracy of the force density function and provides the basis for further study of thermo-mechanical coupling behaviors when engaged in using micro-textured ball-end milling cutters for the cutting of titanium.

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