Burr formation in face milling of cast iron with different milling cutter systems

Abstract

Two face milling cutter systems, both with PCBN (polycrystalline cubic boron nitride) tools, were used to study burr formation in high-speed machining of grey cast iron under various cutting conditions. Surface roughness parameters R a and R t , tool life (based on¯ank wear, VB max ) and burr formation (length of the burr, h) were recorded and used for comparing machining performance. The best performance in terms of tool life and surface roughness was obtained with the milling cutter system consisting of 24 teeth and 24 square wiper inserts. Machining with this cutter con®guration produced acceptable surface roughness values, well below the rejection criterion, after machining a batch of 3000 motor blocks in addition to achieving a signi®cant reduction in the burr length. NOTATIONdoc depth of cut (mm) f z feed per tooth (mm) h maximum roughness height (mm) PCBN polycrystalline cubic boron nitride R a average roughness (mm) R t maximum roughness height (mm) V c cutting speed (m/min) V f feed rate (mm/min) VB max maximum¯ank wear (mm) m exit angle (deg) À r approach angle (deg)

Artificial intelligence for automatic prediction of required surface roughness by monitoring wear on face mill teeth

“…Much of the research devoted to the study of surface roughness in face milling (Diniz and Filho 1999;Caldeirani Filho and Diniz 2002;De Souza et al 2003, 2005De Escalona and Maropoulos 2010;Prasad et al 2011;Houchuan et al 2015;Liu et al 2016;Shi et al 2016;Werda et al 2017) takes tool wear into account. Diniz and Filho (1999) studied the influence of the relative positions of tool and workpiece on tool life, tool wear, and surface finish in the face milling process, taking tool wear into account.…”

“…Caldeirani Filho and Diniz (2002) investigated the influence of cutting speed and feed per tooth on tool life and the surface roughness of machined surfaces during mechanical milling, taking into account tool wear. De Souza et al (2003) defined the parameters of surface roughness, Ra, tool life, and burr formation and used them when comparing the performances of two face-milling cutter systems with PCBN (polycrystalline citric boron nitrite) tools. De Souza et al (2005) defined the parameters of surface roughness, waviness, tool life (based on flank wear), and burr formation and used them to compare the performance of the A system with 24Si 3 N 4 ceramic inserts and the B system in face milling.…”

“…Werda et al (2017) compared tool life and surface roughness in the milling of X100CrMoV5 mold steel under different lubrication conditions: dry machining and minimum quantity lubrication (MQL). Even though many authors (Diniz and Filho 1999;Caldeirani Filho and Diniz 2002;De Souza et al 2003, 2005De Escalona and Maropoulos 2010;Prasad et al 2011;Houchuan et al 2015;Liu et al 2016;Shi et al 2016;Werda et al 2017) have presented the results of surface roughness studies that take into account tool wear, no solutions to the problem of how to establish a comprehensive correlation of surface roughness, tool wear, and processing time have been advanced from the perspective of managing these settings in automated production. This task is however made possible with AI.…”

Machining Burrs Formation & Deburring of Aluminium Alloys

“…For instance, a sharp cutting edge tool with a positive rake angle in the case of a milling operation avoids built-up edge formation, thus decreasing burr formation [18]. As presented in [54], tool wear increases the contact area of the burr-tool interface, and consequently, increases the cutting forces and stress distributions ( Figure 9). Tool wear may physically occur on two sides of the cutting tool, mainly on the rake face and the flank face, thereby forming crater wear and flank wear.…”

“…However, a certain level of coating influence on slot milling burrs was observed in [24]. According to [31,54,55], the tool condition and cutting parameters used, in particular, the feed rate, are the main governing factors affecting burr formation. For instance, a sharp cutting edge tool with a positive rake angle in the case of a milling operation avoids built-up edge formation, thus decreasing burr formation [18].…”