Cutting force, tool wear and surface roughness in high-speed milling of high-strength steel with coated tools

Li, Yuan; Zheng, Guangming; Zhang, Xu; Cheng, Xiang; Yang, Xianhai; Xu, Renjie

doi:10.1007/s12206-019-1033-3

Cited by 40 publications

(17 citation statements)

References 19 publications

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“…Materials harder to process are widely used in the aircraft, automotive, shipbuilding and energy industries for the production of complex and varied components; therefore, materials based on nickel, titanium and steels with improved mechanical properties have been investigated in order to understand the factors degrading the machining process thoroughly. In recent decades, various milling methods have been investigated and analysed to increase productivity [1,[13][14][15], the subject of the investigation also included the following aspects: high-speed machining with respect to the removed material [2,13,14]; simulation methods aiming to implement different control models and the real behaviour of machines to eliminate machine failure and downtime [16,17]; adjusting tool feeds aiming to optimize the production cycle time; process monitoring to evaluate tool wear for titanium or nickel-based alloys [1,18]. The possibilities of the predictive model are control of the machining process in order to reduce vibrations, increase the stability of the cut and efficiency of the cutting process [19]; and trochoidal milling in connection with finish operations in machining superalloys based on nickel [20][21][22].…”

Section: Research Of Trochoidal Millingmentioning

confidence: 99%

Analysis and Prediction of the Machining Force Depending on the Parameters of Trochoidal Milling of Hardened Steel

et al. 2020

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Current demands on quality are the engine of searching for new progressive materials which should ensure enough durability in real conditions. Due to their mechanical properties, however, they cannot be applied to conventional machining methods. In respect to productivity, one of the methods is the finding of such machining technologies which allow achieving an acceptable lifetime of cutting tools with an acceptable quality of a machined surface. One of the mentioned technologies is trochoidal milling. Based on our previous research, where the effect of changing cutting conditions (cutting speed, feed per tooth, depth of cut) on tool lifetime was analysed, next, we continued with research on the influences of trochoid parameters on total machining force (step and engagement angle) as parameters adjustable in the CAM (computer-aided machining) system. The main contribution of this research was to create a mathematical-statistical model for the prediction of cutting force. This model allows setting up the trochoid parameters to optimize force load and potentially extend the lifetime of the cutting tool.

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Section: Research Of Trochoidal Millingmentioning

confidence: 99%

Analysis and Prediction of the Machining Force Depending on the Parameters of Trochoidal Milling of Hardened Steel

et al. 2020

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“…Using the Minitab 16 statistical software to solve the equation (1) to ensure the minimum of tool wear with the constraints as in equations (2) and (3), the optimization graph for the tool wear was obtained and shown in Fig. 13.…”

Section: < ≤ 250( )mentioning

confidence: 99%

“…In recent years, the effect of cutting parameters on the tool wear and other machining characteristics was investigated to improve the quality and efficiency of machining processes many studies were performed to investigate. This research direction was performed in the different machining processes such as milling [1][2][3], turning [4][5][6], drilling [7], etc. to machine the different products.…”

Section: Introductionmentioning

confidence: 99%

A Study on the Tool Wear in Milling Process of the Gleason Spiral Bevel Gear

Thinh¹,

Dong²,

Quoc³

2020

Adv. sci. technol. eng. syst. j.

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“…Up to now, many studies were performed to evaluate the effect of technological parameters and cutting conditions on the tool wear and machining surface roughness to improve the quality Engineering and reduce the cost and time of machining processes. These studies were performed with the normal cutting conditions and with different machining methods such as grinding [1], drilling [2], turning [3][4][5][6], milling [7][8][9][10], and so on. In machining processes, the tool wear and surface roughness in these were investigated and modeled following two directions that were theoretical modelling and experimental modelling.…”

Section: Introductionmentioning

confidence: 99%

Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

et al. 2021

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In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

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Cutting force, tool wear and surface roughness in high-speed milling of high-strength steel with coated tools

Cited by 40 publications

References 19 publications

Analysis and Prediction of the Machining Force Depending on the Parameters of Trochoidal Milling of Hardened Steel

Analysis and Prediction of the Machining Force Depending on the Parameters of Trochoidal Milling of Hardened Steel

A Study on the Tool Wear in Milling Process of the Gleason Spiral Bevel Gear

Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

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