scholarly journals Temperature Field of Tool Engaged Cutting Zone for Milling of Titanium Alloy with Ball-End Milling

Micromachines ◽  
2018 ◽  
Vol 9 (12) ◽  
pp. 672 ◽  
Author(s):  
Shucai Yang ◽  
Chunsheng He ◽  
Minli Zheng ◽  
Quan Wan ◽  
Yuhua Zhang
Keyword(s):  
Titanium Alloy ◽  
Temperature Field ◽  
Thermal Stress ◽  
Contact Area ◽  
End Milling ◽  
Contact Point ◽  
Cutting Temperature ◽  
Cutting Edge ◽  
Strong Impact ◽  
Ball End Milling

When milling titanium alloy, the cutting temperature has a strong impact on the degree of tool wear and, in turn, tool life and the surface quality of the workpiece. The distribution of the temperature field on a tool’s rake face can be improved through the use of micro-textures, which help to reduce friction and, ultimately, wear on the tool. In this paper we present a new way to measure cutting temperature and examine heat distribution when milling titanium alloy with micro-textured ball-end milling tools. We first establish the heat flux density function for the contact area between the workpiece and the tool and then for the rest of the tool. Thermal stress simulation shows that adhesive wear tends to happen in the contact area and on the flank face, rather than at the tip of the tool, with the temperature distribution gradient for the rest of the tool being more uniform. The maximum value for thermal stress on the cutting edge was 2.0782 × 106 Pa. This decrease as you move away from the cutting edge along the contact area between the tool and the workpiece. Maximum deformation of the tool is also mainly concentrated at the principal contact point, with a value of 1.9445 × 10−9 m. This, too, decreases as you move away from the cutting edge and into the rest of the contact area. This research provides the basis for the optimization of tool structure and further investigation of the thermo-mechanical coupling behavior of micro-textured ball-end milling cutters when milling titanium alloy.

scholarly journals Study on mechanical properties of titanium alloy with micro-texture ball-end milling cutter under different cutting edges

2020 ◽  
Vol 12 (7) ◽  
pp. 168781402090842
Author(s):  
Shucai Yang ◽  
Shuai Su ◽  
Xianliang Wang ◽  
Wei Ren
Keyword(s):  
Titanium Alloy ◽  
End Milling ◽  
Cutting Edge ◽  
Milling Force ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Edge Geometry ◽  
Optimum Parameters ◽  
Cutting Surface ◽  
Texture Parameters

When precision cutting titanium alloy, the cutting part of cutting tool is mainly concentrated in the cutting edge area, so there is a strong emphasis upon the cutting edge’s geometric parameters. Studies have found that putting a micro-texture on the cutting surface can reduce the cutting force. This article looks at the milling force involved in cutting titanium alloy with a micro-textured ball-end milling cutter with different shaped cutting edges. First, a milling model relating to different cutting edges is established based on the traditional model of milling force. Then, the effects of different cutting edge geometry parameters and micro-texture parameters on milling force are simulated and tested using a finite element method. With milling force serving as the evaluation index, the optimum micro-texture parameters for a blunt circular cutting edge are a micro-pit diameter of 40 μm, a distance between micro-pits of 175 μm, a distance from the cutting edge of 110 μm, and a blunt circle radius of 60 μm. For a negative chamfer edge, the optimum parameters were a micro-pit diameter of 50 μm, a distance between micro-pits of 175 μm, a distance from the cutting edge of 120 μm, an edge width of 200 μm, and an edge angle of 10°.

Accurate preparation of mesoscopic geometric characteristics of ball end milling cutter and optimization of cutting performance

2021 ◽  
pp. 095440542110285
Author(s):  
Shucai Yang ◽  
Pei Han ◽  
Xiao Liu ◽  
Xin Tong
Keyword(s):  
Titanium Alloy ◽  
Laser Processing ◽  
End Milling ◽  
Cutting Temperature ◽  
Processing Parameters ◽  
Cutting Performance ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Edge Radius ◽  
Blunt Edge

According to the difficult machinability of titanium alloy, the research shows that the surface micro-textured technology can reduce the friction force and cutting temperature in the cutter-workpiece contact area. Starting with the precise preparation of micro textures by laser processing technology, this paper takes ball-end milling cutter milling titanium alloy as the research object, studies the influence of laser processing parameters on micro-textured size parameters, and optimizes the laser processing parameters as follows: laser power P = 40 W, scanning speed V = 1700 mm/s, scanning times N = 7 times, and spot diameter D = 40 μm. The distribution of temperature field and stress field during laser processing is analyzed, and the accuracy of the influence rule of laser processing parameters on micro-textured size parameters is verified, thus realizing the purpose of accurately preparing micro textures. The interactive influence of mesoscopic geometric features on the cutting performance of ball-end milling cutter is analyzed, and the genetic algorithm is used to optimize the parameters. The results show that the main factor affecting the force-heat characteristics of the tool is the blunt edge radius, and the interaction between the blunt radius of the cutting edge and the distance from blade is obvious. The optimized mesoscopic geometric parameters are as follows: the blunt edge radius is 20 μm, and the distance from blade is 110 μm, the micro-textured diameter is 30 μm, and the micro-textured spacing is 175 μm. The research content of this paper lays a foundation for efficient cutting of titanium alloy materials.

Finite Element Method Predicts the Distribution of Cutting Temperature in Diamond Turning

2007 ◽  
Vol 339 ◽  
pp. 100-105
Author(s):  
Wen Jun Zong ◽  
Dan Li ◽  
T. Sun ◽  
K. Cheng
Keyword(s):  
Temperature Field ◽  
Contact Area ◽  
Cutting Temperature ◽  
Rake Angle ◽  
Diamond Turning ◽  
Cutting Edge ◽  
Fe Model ◽  
Cutting Edge Radius ◽  
Edge Radius ◽  
Distribution Shape

In this paper, a coupled thermo-mechanical FE model is proposed to simulate the cutting temperature’s distribution produced in diamond turning. Simulated results indicate that the heat converting from plastic work has prominent effects on the distribution shape of cutting temperature field, and with an increment in cutting velocity, the locating site of maximal cutting temperature shifts from the contact area between tool tip and chip root to the contact area between rake face and chip. Cutting edge radius has minute influence on the distribution shape of cutting temperature field, but the bigger the cutting edge radius is, the higher the maximum cutting temperature in cutting region. Rake angle also has slight effects on the maximal temperature when it is more than 10○. While clearance angle reaches to 6○, the maximum cutting temperature approaches the smallest.

scholarly journals Study on Milling Temperature of Titanium Alloy with Micro-Textured Ball End Milling Cutter under Radius of Blunt Edge

2020 ◽  
Vol 10 (2) ◽  
pp. 587
Author(s):  
Shucai Yang ◽  
Shuai Su ◽  
Xianli Liu ◽  
Pei Han
Keyword(s):  
Titanium Alloy ◽  
End Milling ◽  
Cutting Temperature ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Optimum Parameters ◽  
Cutting Heat ◽  
Milling Temperature ◽  
Combined Action ◽  
Blunt Edge

A high temperature is produced in the process of precision milling of titanium alloy, and the cutting temperature can be effectively reduced by placing a micro-texture on the tool surface. In order to study the milling temperature of micro-textured ball-end milling cutter in milling titanium alloy under the combined action of a blunt radius with different edges and a micro-texture with different parameters, a new method based on micro-element theory and the generation and transmission of cutting heat has been established. At the same time, the influence of different radii of blunt edges on the milling temperature is simulated by the finite element method and experimentally verified to explore the influence of different radii of a blunt edge and micro-texture parameters on the milling temperature. Taking the milling temperature as the evaluation index, the optimum parameters of micro-circular pit texture are as follows: the diameter of micro-circular pit is 40 micron, pit spacing is 225 micron, distance from cutting edge is 100 microns, and radius of the blunt edge is 60 microns.

scholarly journals Optimization of Texture Density Distribution of Carbide Alloy Micro-Textured Ball-End Milling Cutter Based on Stress Field

2020 ◽  
Vol 10 (3) ◽  
pp. 818
Author(s):  
Minli Zheng ◽  
Chunsheng He ◽  
Shucai Yang
Keyword(s):  
Wear Resistance ◽  
Stress Field ◽  
Density Distribution ◽  
Titanium Alloys ◽  
Contact Area ◽  
End Milling ◽  
Variable Density ◽  
Milling Cutter ◽  
Ball End Milling ◽  
Texture Density

The insertion of micro-textures plays a role in reducing friction and increasing wear resistance of the cutters, which also has a certain impact on the stress field of the cutter during milling. Therefore, in order to study the mechanisms of friction reduction and wear resistance of micro-textured cutters in high speed cutting of titanium alloys, the dynamic characteristics of the instantaneous stress field during the machining of titanium alloys with micro-textured cutters were studied by changing the distribution density of the micro-textures on the cutter. First, the micro-texture insertion area of the ball-end milling cutter was theoretically analyzed. Then, variable density micro-textured ball-end milling cutters and non-texture cutters were used to cut titanium alloy, and the mathematical model of milling force and cutter-chip contact area was established. Then, the stress density functions of different micro-texture density cutters and non-texture cutters were established to simulate the stress fields of variable density micro-textured ball-end milling cutters and non-texture cutters. Finally, the genetic algorithm was used to optimize the variable density distribution of micro-textured cutters in which the instantaneous stress field of the cutters was taken as the optimization objective. The optimal solution for the variable density distribution of the micro-textured cutter in the cutter-chip tight contact area was obtained as follows: the texture distribution densities in the first, second, and third areas are second, and third areas are 0.0905, 0.0712, and 0.0493, respectively.

scholarly journals Effect of Tool Orientation on Surface Integrity During Ball End Milling of Titanium Alloy TC17

Procedia CIRP ◽  
2016 ◽  
Vol 56 ◽  
pp. 143-148 ◽  
Author(s):  
Pan Yang ◽  
Changfeng Yao ◽  
Shaohua Xie ◽  
Dinghua Zhang ◽  
Dou Xing Tang
Keyword(s):  
Titanium Alloy ◽  
Surface Integrity ◽  
End Milling ◽  
Tool Orientation ◽  
Ball End Milling

A HIGHER FIDELITY MODELING OF THE CUTTING EDGE OF BALL-END MILLING TOOL

2011 ◽  
Vol 10 (01) ◽  
pp. 101-108 ◽  
Author(s):  
XIULIN SUI ◽  
IMRE HORVATH ◽  
JIATAI ZHANG ◽  
PING ZHANG
Keyword(s):  
End Milling ◽  
Milling Process ◽  
Cutting Edge ◽  
Ball End Milling ◽  
Machining Conditions ◽  
Milling Tool ◽  
Efficient Planning ◽  
Pilot Implementation ◽  
Physical Changes ◽  
Milling Forces

Ball-end milling tools have been widely used in machining of complex freeform surfaces. The precision and efficiency of ball-end milling process can be improved by an accurate modeling of the tools, the tools' paths and the machining conditions. However, only rough geometric models have been applied so far, which do not consider the machining conditions and the physical changes. To achieve the best results, an accurate modeling of the cutting edge and the physical behavior of the entire cutter is needed. This paper proposes an articulated model that enumerates both the geometric characteristics and the physical effects acting on the cutting edge-segment of a ball-end milling cutter. The model considers the deformations caused by the milling forces, vibration, spindle eccentricity, together with thermal deformation and wear of the cutter. The mathematical description of the behavior has been transferred into a computational model. The pilot implementation has been tested in a practical application. The first findings show that the proposed theoretical model and implementation provide sufficiently precise information about the behavior of the cutter in virtual simulations; hence it can be the basis of a fully fledged and more efficient planning of milling processes.

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