An Analytical Approach to Cutter Edge Temperature Prediction in Milling and Its Application to Trochoidal Milling

Deng, Qi; Mo, Rong; Chen, Zezhong C.; Chang, Zhiyong

doi:10.3390/app10051746

Cited by 12 publications

(8 citation statements)

References 34 publications

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“…In order to evaluate the efficiency of trochoidal milling, relative specific energy, U r , will be utilized. The relative specific energy can be defined as the ratio of the multiplication of maximum resultant force, F R , and cutting speed, v, to the material removal rate, MRR, equation (8). Figure 11 illustrates the relationship between the machining conditions and the relative specific energy.…”

Section: Relative Specific Energymentioning

confidence: 99%

“…Therefore, cutting forces, cutting temperature, and tool wear are lower. 1,4,5 Trochoidal milling is efficient in the machining of difficult-to-cut materials such as Ti-6Al-4V, 5–8 duplex stainless steel, 9 Inconel superalloys, 10,11 etc., in high-speed machining 12,13 and machining of corners. 14,15 Uddin et al proved experimentally that trochoidal milling is suitable for deep and narrow grooves.…”

Section: Introductionmentioning

confidence: 99%

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Effects of process parameters on cutting forces, material removal rate, and specific energy in trochoidal milling

Wagih,

Hassan,

El-Hofy

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Trochoidal milling has been developed to enhance tool life during slot machining. It is characterized by reduced cutting forces, cutting temperature, and tool wear as compared to conventional milling processes. It is effective in machining difficult-to-cut materials, high-speed machining, and groove corners. However, this process has not been deeply investigated enough to discover its advantages and optimize its parameters. A full factorial design of 144 experiments has been applied in this paper to investigate extensively the effects of axial depth of cut, feed rate, and trochoidal step on material removal rate, cutting forces, and specific energy in trochoidal milling. Trochoidal step and axial depth of cut almost have the same contributions on cutting forces by 32% and 31% respectively, followed by feed rate by 25%. Feed rate, trochoidal step, and axial depth of cut influence the material removal rate by 37%, 30%, and by 19% respectively. The contributions of feed rate, trochoidal step, and axial depth of cut on relative specific energy are 57%, 24%, and 8% respectively. The increase of axial depth of cut increases the maximum resultant force till a threshold value, then it stabilizes. This behavior occurred due to the increase of the maximum engagement angle to a certain limit, then it does not increase any more. Both feed rate and trochoidal step linear affect maximum resultant force and material removal rate, while the relationships are non-linear for specific energy. It is recommended to machine slots in full depth with the highest possible trochoidal step and feed rate, considering the increase of tool wear and surface roughness. It is preferred to use a cutting tool of a large helix angle and small diameter to reduce the threshold axial depth of cut. Overall, this study is significant in characterizing, designing, and optimizing of trochoidal milling through experimental work.

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Section: Relative Specific Energymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effects of process parameters on cutting forces, material removal rate, and specific energy in trochoidal milling

Wagih,

Hassan,

El-Hofy

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…IOP Publishing doi:10.1088/1757-899X/1290/1/012002 2 In [11] a practical approach to predict the cutting temperature in trochoidal milling was established using different ways, and finally, as the authors show, the cutter edge temperature patterns during trochoidal and side milling were extensively analyzed.…”

Section: Introductionmentioning

confidence: 99%

Temperature during the milling process of aluminum alloys using contact and non-contact methods

Patru,

Bica,

Panduru

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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In this paper some experimental determinations on the temperature during the milling process of aluminum alloys (5083, 6082 and 7075) were conducted, by using two methods: with contact and non-contact, for the different feed speeds. For this reason, an adequate installation was used, so that the temperature can be measure simultaneously. The results are presented using graphical dependencies of the temperature as function of the feed speed, for each type experiment, and then a synthesis regarding the maximum values of the temperature as function of the material type and the value of the feed speeds is presented.

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“…Trochoidal milling, Fig. 1, is a process that has been developed to extend the cutting tool life by increasing the cutting tool cooling time [1][2][3]. In this process, a rotating endmill moves in a predetermined path, where after each revolution, it translates linearly a distance defined as a trochoidal step.…”

Section: Introductionmentioning

confidence: 99%

Investigating the effects of trochoidal milling parameters on the waviness and surface roughness of P20 alloy steel slots: Analytical and Experimental

Wagih,

Maher,

Hassan

2023

Preprint

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This paper aims to study, analytically and experimentally, the effects of trochoidal milling parameters on the waviness and the surface roughness of P20 alloy steel slots. The considered process parameters in this paper are the axial depth of cut, trochoidal step, and feed rate, in addition to the slot width. A geometrical analytical model of the tool cutting edges imprints has been developed to explain the of waviness and surface roughness at the slot walls and bottom. Results of this model proved that increasing the slot width significantly reduces the slot walls waviness, while increasing the feed rate or the trochoidal step increases the waviness of the slot left and right walls respectively. The experimental results proved that the axial depth of cut has not a significant effect on the slot walls waviness, and the tool edges imprints have the greatest effect on the bottom surface roughness. The surface roughness of the slot bottom decreases from left to right. Moreover, increasing the feed rate significantly increased the bottom surface roughness by 25%, 29%, and 29% at the left wall, middle, and right wall of the machined slot, respectively. However, increasing the axial depth of cut, significantly increased the bottom surface roughness only at the left wall and the middle of the machined slot by 11% and 19%, respectively. Experimental and analytical results of waviness and surface roughness were in good agreements which verifies the potential of using the developed model to predict the slot surface texture during circular trochoidal milling.

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An Analytical Approach to Cutter Edge Temperature Prediction in Milling and Its Application to Trochoidal Milling

Cited by 12 publications

References 34 publications

Effects of process parameters on cutting forces, material removal rate, and specific energy in trochoidal milling

Effects of process parameters on cutting forces, material removal rate, and specific energy in trochoidal milling

Temperature during the milling process of aluminum alloys using contact and non-contact methods

Investigating the effects of trochoidal milling parameters on the waviness and surface roughness of P20 alloy steel slots: Analytical and Experimental

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