Chip Temperature Measurement in the Cutting Area During Rough Milling Magnesium Alloys with a Kordell Geometry End Mill

Kuczmaszewski, Józef; Zagórski, Ireneusz; Zgórniak, P.

doi:10.12913/22998624/146851

Cited by 3 publications

(5 citation statements)

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“…When the milling process is performed using carbide end mills with standard cutting edge geometry [12], the temperature in the cutting zone is frequently below 350°C, therefore the milling process can be regarded as safe when conducted under these machining conditions. A similar observation was made for the carbide tool with a Kordell geometry end mill [10]. For most cases, the chip temperature did not exceed a value of 330 °C (for f z =0.03 mm/tooth T max was approx.…”

Section: Introductionsupporting

confidence: 73%

“…In machining processes, chip temperature in the cutting zone is usually measured with an infrared camera [2,3,4,7,9,10,11,12]. For example, in the early years of the twenty-first century a study [9] conducted on milling AZ91HP alloy by the MQL method reported that the maximum chip temperature in this process was about 290°C.…”

Section: Introductionmentioning

confidence: 99%

“…500 °C). Similar analyses were conducted for high-speed rough milling [2,10,11,12] to determine the maximum chip temperature during machining. When the milling process is performed using carbide end mills with standard cutting edge geometry [12], the temperature in the cutting zone is frequently below 350°C, therefore the milling process can be regarded as safe when conducted under these machining conditions.…”

Section: Introductionmentioning

confidence: 99%

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Safety in Rough Milling of Magnesium Alloys Using Tools with Variable Cutting Edge Geometry

Zagórski¹

2023

Adv. Sci. Technol. Res. J.

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This paper presents the results of a study investigating the problem of safety in dry milling magnesium alloy AZ91D. Selected indicators of safe machining were analyzed, including time to ignition, ignition temperature, chip mass and morphology. Experiments were performed using carbide end mills with a variable edge helix angle. It was observed that magnesium alloys could be dry milled without the risk of chip ignition. The milling process conducted with the axial depth of cut a p set to 6 mm was found to be optimum (a great amount of leading fraction A was produced). Unfortunately, however, some machining conditions proved to be inductive to the formation of chip powder known as magnesium dust. For most cases, chips obtained using the tool with λ s 50° had higher unit mass than those obtained with λ s 20°. Metallographic images of chips confirmed the safe range of the machining parameters employed (no partial melting or burn marks were observed). Determined on a specially designed test stand outside of the machine tool, time to ignition can be an effective parameter for performing simplified chip ignition simulations.

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Section: Introductionsupporting

confidence: 73%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Safety in Rough Milling of Magnesium Alloys Using Tools with Variable Cutting Edge Geometry

Zagórski¹

2023

Adv. Sci. Technol. Res. J.

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“…The observed chip fragmentation (the quantity of chip fractions) is lower at the tool rake angle γ o = 30 • . In [23,34], a controlled chip ignition was performed on a specially designed and made chip flammability test stand, outside the machine. The so-called time to ignition of different chip fractions was determined.…”

Section: Chip Shape and Geometrymentioning

confidence: 99%

“…Therefore, a much broader approach is required to comprehensively assess the quality of the machined surface. Therefore, it is justified to extend the research to a wider range of technological parameters, including 3D; however, one should take into account the tendency of magnesium alloys to self-ignition with a sudden increase in temperature in the cutting zone [30,34]. Additionally, attention should be paid to the characteristics of the chips produced in machining.…”

Section: Objective Of Research and Noveltiesmentioning

confidence: 99%

Research, Modelling and Prediction of the Influence of Technological Parameters on the Selected 3D Roughness Parameters, as Well as Temperature, Shape and Geometry of Chips in Milling AZ91D Alloy

et al. 2022

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The main purpose of the study was to define the machining conditions that ensure the best quality of the machined surface, low chip temperature in the cutting zone and favourable geometric features of chips when using monolithic two-teeth cutters made of HSS Co steel by PRECITOOL. As the subject of the research, samples with a predetermined geometry, made of AZ91D alloy, were selected. The rough milling process was performed on a DMU 65 MonoBlock vertical milling centre. The machinability of AZ91D magnesium alloy was analysed by determining machinability indices such as: 3D roughness parameters, chip temperature, chip shape and geometry. An increase in the feed per tooth fz and depth of cut ap parameters in most cases resulted in an increase in the values of the 3D surface roughness parameters. Increasing the analysed machining parameters did not significantly increase the instantaneous chip temperature. Chip ignition was not observed for the current cutting conditions. The conducted research proved that for the adopted conditions of machining, the chip temperature did not exceed the auto-ignition temperature. Modelling of cause-and-effect relationships between the variable technological parameters of machining fz and ap and the temperature in the cutting zone T, the spatial geometric structure of the 3D surface “Sa” and kurtosis “Sku” was performed with the use of artificial neural network modelling. During the simulation, MLP and RBF networks, various functions of neuron activation and various learning algorithms were used. The analysis of the obtained modelling results and the selection of the most appropriate network were performed on the basis of the quality of the learning and validation, as well as learning and validation error indices. It was shown that in the case of the analysed 3D roughness parameters (Sa and Sku), a better result was obtained for the MLP network, and in the case of maximum temperature, for the RBF network.

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Methodology of Chip Temperature Measurement and Safety Machining Assessment in Dry Rough Milling of Magnesium Alloys Using Different Helix Angle Tools

Zagórski,

Zgórniak,

Habrat

et al. 2024

Materials

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This paper presents the methodology of measuring chip temperature in the cutting zone in the rough milling of magnesium alloys. Infrared measurements are taken to determine the effect of variable cutting speed, feed per tooth, and depth of cut on the maximum temperature of chips. Thermal images of chip temperature for a generated collective frame and corresponding histograms are presented. Chip temperatures are presented in numerical terms as median and average values; maximum and minimum values; range; and standard deviation. Box plots are also shown for selected machining conditions. The problems arising during signal recording with a mean emissivity coefficient ε = 0.13, a value which is dedicated during machining magnesium alloys, are discussed in detail. Chip temperatures obtained in the tests do not exceed approx. 420 °C. Therefore, the dry rough milling process carried out with carbide tools with different blade geometries can be considered safe for a wide range of machining parameters. The proposed methodology of chip temperature measurement and result processing is a new and effective approach to safety assessment in the dry milling of magnesium alloys.

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Chip Temperature Measurement in the Cutting Area During Rough Milling Magnesium Alloys with a Kordell Geometry End Mill

Cited by 3 publications

References 0 publications

Safety in Rough Milling of Magnesium Alloys Using Tools with Variable Cutting Edge Geometry

Safety in Rough Milling of Magnesium Alloys Using Tools with Variable Cutting Edge Geometry

Research, Modelling and Prediction of the Influence of Technological Parameters on the Selected 3D Roughness Parameters, as Well as Temperature, Shape and Geometry of Chips in Milling AZ91D Alloy

Methodology of Chip Temperature Measurement and Safety Machining Assessment in Dry Rough Milling of Magnesium Alloys Using Different Helix Angle Tools

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