Effect of Cutting Parameters on Tool Wear when Trochoidal Pocket Milling Ti6Al4V

Sharif, Safian; Ramli, Ahmad Termizi; Said, A.Y.M.; Karim, Z.; Rahim, Erween Abd; Sani, Amiril Sahab Abdul

doi:10.30880/ijie.2019.11.04.017

Cited by 5 publications

(4 citation statements)

References 10 publications

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“…In circular-type trochoidal milling the exact material removal rate, MRR, can be calculated from equation (7). Each axial depth of cut, feed rate, and trochoidal step affects the material removal rate significantly.…”

Section: Materials Removal Ratementioning

confidence: 99%

“…The decrease of relative specific energy is induced by the increase of feed rate by 57%, trochoidal step by 24%, and axial depth of cut by 8%. (7). In trochoidal milling, it is recommended to machine slots in full depth with high trochoidal step and feed rate, taking into consideration the increase of tool wear and surface roughness.…”

Section: Declaration Of Conflicting Interestsmentioning

confidence: 99%

“…Therefore, cutting forces, cutting temperature, and tool wear are lower. 1,4,5 Trochoidal milling is efficient in the machining of difficult-to-cut materials such as Ti-6Al-4V, 5–8 duplex stainless steel, 9 Inconel superalloys, 10,11 etc., in high-speed machining 12,13 and machining of corners. 14,15 Uddin et al proved experimentally that trochoidal milling is suitable for deep and narrow grooves.…”

Section: Introductionmentioning

confidence: 99%

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Effects of process parameters on cutting forces, material removal rate, and specific energy in trochoidal milling

Wagih,

Hassan,

El-Hofy

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Trochoidal milling has been developed to enhance tool life during slot machining. It is characterized by reduced cutting forces, cutting temperature, and tool wear as compared to conventional milling processes. It is effective in machining difficult-to-cut materials, high-speed machining, and groove corners. However, this process has not been deeply investigated enough to discover its advantages and optimize its parameters. A full factorial design of 144 experiments has been applied in this paper to investigate extensively the effects of axial depth of cut, feed rate, and trochoidal step on material removal rate, cutting forces, and specific energy in trochoidal milling. Trochoidal step and axial depth of cut almost have the same contributions on cutting forces by 32% and 31% respectively, followed by feed rate by 25%. Feed rate, trochoidal step, and axial depth of cut influence the material removal rate by 37%, 30%, and by 19% respectively. The contributions of feed rate, trochoidal step, and axial depth of cut on relative specific energy are 57%, 24%, and 8% respectively. The increase of axial depth of cut increases the maximum resultant force till a threshold value, then it stabilizes. This behavior occurred due to the increase of the maximum engagement angle to a certain limit, then it does not increase any more. Both feed rate and trochoidal step linear affect maximum resultant force and material removal rate, while the relationships are non-linear for specific energy. It is recommended to machine slots in full depth with the highest possible trochoidal step and feed rate, considering the increase of tool wear and surface roughness. It is preferred to use a cutting tool of a large helix angle and small diameter to reduce the threshold axial depth of cut. Overall, this study is significant in characterizing, designing, and optimizing of trochoidal milling through experimental work.

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Section: Materials Removal Ratementioning

confidence: 99%

Section: Declaration Of Conflicting Interestsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Effects of process parameters on cutting forces, material removal rate, and specific energy in trochoidal milling

Wagih,

Hassan,

El-Hofy

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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show abstract

“…[3,4,6,7]. It is efficient in machining under severe conditions [8,9], machining difficult-to-cut materials such as Ti-6Al-4V, duplex stainless steel, Inconel superalloys [5,[10][11][12][13][14], and machining of slots and corners [15,16]. It has been experimentally proved that trochoidal milling is suitable for deep and narrow grooves [17].…”

Section: Introductionmentioning

confidence: 99%

Investigating the effects of trochoidal milling parameters on the waviness and surface roughness of P20 alloy steel slots: Analytical and Experimental

Wagih,

Maher,

Hassan

2023

Preprint

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This paper aims to study, analytically and experimentally, the effects of trochoidal milling parameters on the waviness and the surface roughness of P20 alloy steel slots. The considered process parameters in this paper are the axial depth of cut, trochoidal step, and feed rate, in addition to the slot width. A geometrical analytical model of the tool cutting edges imprints has been developed to explain the of waviness and surface roughness at the slot walls and bottom. Results of this model proved that increasing the slot width significantly reduces the slot walls waviness, while increasing the feed rate or the trochoidal step increases the waviness of the slot left and right walls respectively. The experimental results proved that the axial depth of cut has not a significant effect on the slot walls waviness, and the tool edges imprints have the greatest effect on the bottom surface roughness. The surface roughness of the slot bottom decreases from left to right. Moreover, increasing the feed rate significantly increased the bottom surface roughness by 25%, 29%, and 29% at the left wall, middle, and right wall of the machined slot, respectively. However, increasing the axial depth of cut, significantly increased the bottom surface roughness only at the left wall and the middle of the machined slot by 11% and 19%, respectively. Experimental and analytical results of waviness and surface roughness were in good agreements which verifies the potential of using the developed model to predict the slot surface texture during circular trochoidal milling.

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Analysis and development of elliptical tool path in trochoidal milling

Wagih,

Maher,

El-Hofy

et al. 2023

CIRP Journal of Manufacturing Science and Technology

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Effect of Cutting Parameters on Tool Wear when Trochoidal Pocket Milling Ti6Al4V

Cited by 5 publications

References 10 publications

Effects of process parameters on cutting forces, material removal rate, and specific energy in trochoidal milling

Effects of process parameters on cutting forces, material removal rate, and specific energy in trochoidal milling

Investigating the effects of trochoidal milling parameters on the waviness and surface roughness of P20 alloy steel slots: Analytical and Experimental

Analysis and development of elliptical tool path in trochoidal milling

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