Assessment of tool path strategies for milling complex surfaces in hardened H13 steel

Magalhães, Laurence Colares; Ferreira, João Carlos Espíndola

doi:10.1177/0954405418755824

Cited by 12 publications

(9 citation statements)

References 40 publications

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“…The range of the measured values of the surface roughness is same like in [13] and [18] in the case of similar circumstances. The effect of the tool path on the surface roughness is presented in [18]. The tool path direction from x to y axis increased the surface roughness in our research, but the nature of the surfaces (convex or concave) has no effect on it.…”

Section: Discussionsupporting

confidence: 57%

“…In the case of the milling parallel to the x axis, during one run the working diameter, load of the tool, and tool deformation are constant. But in case of other direction, they are changed in every position of the tool, as [18] presented too. In the case of milling parallel to the y axis there is the fastest changing of these parameters.…”

Section: Discussionmentioning

confidence: 99%

“…The real surface roughness is better than the scallop height. Magalhales and Ferreira [18] investigate three milling strategies from the viewpoint of surface roughness and productivity in case of a convex spherical test part. The radial strategy ensures the best surface quality and the worst machining time.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

The Effect of the Feed Direction on the Micro- and Macro Accuracy of 3D Ball-end Milling of Chromium-Molybdenum Alloy Steel

2019

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The machining of free form surfaces is one of the most challenging problems in the field of metal cutting technology. The produced part and machining process should satisfy the working, accuracy, and financial requirements. The accuracy can describe dimensional, geometrical, and surface roughness parameters. In the current article, three of them are investigated in the case of the ball-end milling of a convex and concave cylindrical surface form 42CrMo4 steel alloy. The effect of the tool path direction is investigated and the other cutting parameters are constant. The surface roughness and the geometric error are measured by contact methods. Based on the results, the surface roughness, dimensional error, and the geometrical error mean different aspects of the accuracy, but they are not independent from each other. The investigated input parameters have a similar effect on them. The regression analyses result a very good liner regression for geometric errors and shows the importance of surface roughness.

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Section: Discussionsupporting

confidence: 57%

Section: Discussionmentioning

confidence: 99%

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The Effect of the Feed Direction on the Micro- and Macro Accuracy of 3D Ball-end Milling of Chromium-Molybdenum Alloy Steel

2019

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“…1,2 The theoretical toolpath (TTP) is a continuous curve offsetting a distance of cutter radius from the designed surface. 3 However, since current machine tools cannot follow the TTP continuously, the TTP is discretized as cutter location (CL) data. The practical interpolated toolpath (PITP) is the result of linear interpolation of the CL data.…”

Section: Introductionmentioning

confidence: 99%

Geometric deviation reduction method for interpolated toolpath in five-axis flank milling of the S-shaped test piece

Wang

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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Geometric deviation, defined as the distance between the designed surface and the machined surface, is an important component of machining errors in five-axis flank milling of the S-shaped test piece. Since the interpolated toolpath in practical machining process is the approximation of the theoretical toolpath, the geometric deviation caused by the interpolated toolpath appears. To overcome this problem, a novel geometric deviation reduction method is suggested in this study. First, the features of the S-shaped test piece are analyzed. Second, the theoretical toolpath is generated according to the designed surface and the cutter location data is obtained by discretizing the theoretical toolpath. The linear interpolation of the cutter location data is carried out to obtain the interpolated toolpath. Then, the geometric deviation is modeled by calculating the Hausdorff distance between the tool axis trajectory surface based on the interpolated toolpath and the offset surface of the designed surface. Finally, the geometric deviation is reduced by optimizing the cutter location data without inserting more cutter location points. The machining experiment is conducted to verify the effectiveness of the proposed method. The experimental results agree with the simulation results, and both of them indicate the geometric deviation on the machined surface reduces after optimization.

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“…Scandiffio et al 10 analyzed influence of the toolpath direction and tool–workpiece surface contact on machining forces, surface roughness and tool life in machining hardened steel. Magalhaes and Ferreira 11 conducted an experiment of milling the hardened steel H13 and obtained the effect of tool path and cutting parameters on machining efficiency, surface roughness and machining accuracy. Batista et al 12 established a mathematical model of surface roughness produced by high-speed machining with ball-nose end mill.…”

Section: Introductionmentioning

confidence: 99%

Study on the cutting performance in machining assembled hardened steel workpiece with torus cutter

Chen

Gao

Wang

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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Torus cutters are increasingly used in machining high-hardness materials because of high processing efficiency. However, due to the large hardness variation in assembled hardened steel workpiece, the tool wear occurs easily in machining process. This severely affects the machined surface quality. Here, we conduct a research on the tool wear and the machined surface quality in milling assembled hardened steel mold with a torus cutter. The experimental results show the abrasive wear mechanism dominates the initial tool wear stage of the torus cutter. As the tool wear intensifies, the adhesive wear gradually occurs due to the effect of alternating stress and impact load. Thus, the mixing effect of the abrasive and adhesive wears further accelerates tool wear, resulting in occurrence of obvious crater wear band on the rake face and coating tearing area on the flank face. Finally, the cutter is damaged by the fatigue wear mechanism, reducing seriously the cutting performance. With increase of flank wear, moreover, there are increasingly obvious differences in both the surface morphology and the cutting force at the two sides of the joint seam of the assembled hardened steel parts, including larger height difference at the two sides of the joint seam and sudden change of cutting force, as a result, leading to decreasing cutting stability and deteriorating seriously machined surface quality.

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Assessment of tool path strategies for milling complex surfaces in hardened H13 steel

Cited by 12 publications

References 40 publications

The Effect of the Feed Direction on the Micro- and Macro Accuracy of 3D Ball-end Milling of Chromium-Molybdenum Alloy Steel

The Effect of the Feed Direction on the Micro- and Macro Accuracy of 3D Ball-end Milling of Chromium-Molybdenum Alloy Steel

Geometric deviation reduction method for interpolated toolpath in five-axis flank milling of the S-shaped test piece

Study on the cutting performance in machining assembled hardened steel workpiece with torus cutter

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