Comparison of Surface Roughness When Turning and Milling

The machining process using a combination of steep and shallow strategy is the most widely used strategy for the finishing process on complex models that have many areas of steep walls and shallow floors. Using a single machining strategy on the entire model can lead to long machining times and poor surface finish quality. The steep and shallow strategy can efficiently detect parts of the model that have steep contours and those that have shallow contours. In other words, this strategy can analyze the model surface angle at runtime to identify and divide the machining zone based on the slope angle or commonly called the threshold angle. In this context, the selection of the threshold angle is very important when carrying out the finishing process on free-form surfaces to produce a good surface quality. This study was conducted to determine the optimum threshold angle that can produce the minimum surface roughness between steep areas and shallow areas. Threshold angles that were varied were 20°, 30° and 40°. Machining was carried out using Ballnose type cutting tools with a diameter of 6 mm. Then the stepover and stepdown is 0.1 mm for the finishing process on the surface of the propeller product made of Aluminum by using a CNC Milling machine. From the experimental results, the most optimum threshold angle is at an angle of 40° with an average roughness value in the steep area of 1.9 mm and in the shallow area of 1.3mm and a total average roughness of 1.6mm.

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“…Cusp height on constant-Z finishing strategy can be seen in Figure 7, its value can be calculated using the following equation [6]:…”

Section: Figure 7 Cusp Heigh Of Constant-z Startegymentioning

confidence: 99%

Analysis of Threshold Angle Variations on The Quality of Finishing Free-form Surface in CNC Milling Process

Purnomo¹,

Bisono²,

Indrawan³

2022

ijseit

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“…The machining accuracy mainly depends on the extent of the inclination angle, tangential feed, and depth of cut [11] The most used parameters in the quantification of surface quality are the Arithmetic Mean Deviation (Ra) and the Maximum peak to valley height of the profile (Rz). However, it is indicated [12] that these parameters are not always good in the characterization of the machined surface. The results of Yue et al indicated [13] that the original parameters are unsuitable to characterize the textured surfaces, however the Abbot-Firestone curve parameters are more effective for tribological applications.…”

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confidence: 99%

Preliminary Study On the Function-Defining 3D Surface Roughness Parameters in Tangential Turning

Sztankovics

2023

IJIE

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The function-defining three-dimensional (3D) surface roughness parameters (which describe an aspect of the surface quality based on areal topography measurements) are studied on tangentially turned surfaces with different technological parameters in this paper. The 23 factorial design is applied in the planning of experiments. Two levels of depth of cut, cutting speed and feed were chosen for the comprehensive analysis of the tangential turning process. The values of Core Roughness, Reduced Peak Height, Reduced Valley Depth, Skewness and Kurtosis are measured by the application of a 3D areal roughness measurement machine. Equations were determined for the calculation of the studied parameters according to the factorial design method. The results were evaluated in two steps: first the functional parameters derived from the Areal Material Ratio curve were analyzed, then the Skewness and Kurtosis of the assessed area were studied. It is found that a two-fold increase in the cutting speed decreases the Core Roughness Depth, Reduced Peak Height, and Reduced Valley Depth 2-4-fold. The increasing feed rate lowers the presence of inordinately extremes, resulting in a smoother surface. In the point of view of Skewness and Kurtosis, lower cutting speeds and higher feeds are more favorable.

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A case study of hybrid manufacturing of a Ti-6Al-4V titanium alloy hip prosthesis

Festas,

Figueiredo,

Carvalho

et al. 2023

Int J Adv Manuf Technol

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Hybrid manufacturing (HM) is a process that combines additive manufacturing (AM) and subtractive manufacturing (SM). It is becoming increasingly recognized as a solution capable of producing components of high geometric complexity, while at the same time ensuring the quality of the surface finish, rigour and geometric tolerance on functional surfaces. This work aims to study the surface finish quality of an orthopaedic hip resurfacing prosthesis obtained by HM. For this purpose, test samples of titanium alloy Ti-6Al-4V using two Power Bed Fusion (PBF) processes were manufactured, which were finished by turning and 5-axis milling. It was verified that, upon the machining tests, no differences in Ra and Rt were found between the various types of AM. Regarding the type of SM used, 5-axis milling provided lower roughness results with a consistent value of Ra = 0.6 µm. The use of segmented circle mills in 5-axis milling proved to be an asset in achieving a good surface finish. This work successfully validated the concept of HM to produce a medical device, namely, an orthopaedic hip prosthesis.As far as surface quality is concerned, it could be concluded that the optimal solution for this case study is 5-axis milling.

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Comparison of Surface Roughness When Turning and Milling

Cited by 6 publications

References 16 publications

Analysis of Threshold Angle Variations on The Quality of Finishing Free-form Surface in CNC Milling Process

Analysis of Threshold Angle Variations on The Quality of Finishing Free-form Surface in CNC Milling Process

Preliminary Study On the Function-Defining 3D Surface Roughness Parameters in Tangential Turning

A case study of hybrid manufacturing of a Ti-6Al-4V titanium alloy hip prosthesis

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