FEM to predict the effect of feed rate on surface roughness with cutting force during face milling of titanium alloy

Ali, Moaz H.; Khidhir, Basim A.; Ansari, M.N.M.; Mohamed, Bashir

doi:10.1016/j.hbrcj.2013.05.003

Cited by 37 publications

(11 citation statements)

References 10 publications

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“…Graphs E, F and G from Figure 3(a) are in accordance with results from Kumar et al 16 , Thepsonthi and Özel 17 and Thepsonthi and Özel 18 ; which assert that smaller feed rates generate better surface finishes on the piece for micro-milling. The same resuls are also obtained by Ali et al 19 , Karkalos, Galanis, Markopoulos 20 , and Shokrani, Dhokia, Newman 21 , since the since the roughness are geometrically dependent of feed rate.…”

Section: Figure 3 Interactions Graphs Between the Factors Over Surfasupporting

confidence: 82%

Study of Surface Roughness and Burr Formation After Milling of Carbon Fiber/Titanium Stacks

2019

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This work aims to study the influence of cutting parameters (cutting speed, feed rate, cutting depth and tool cutting edge angle) regarding surface roughness and burr formation during the milling of a mixed structure comprised of titanium and carbon fiber (stack). The parameters were varied from maximum to minimum, just as the tool cutting edge angle of the insert, through a full factorial design with 32 trials. The analyses were performed by measuring the surface roughness and burr size along with metallographic analyses through optic microscopy and scanning electron microscopy. The results showed that the surface roughness was higher for carbon fiber and burr size was higher for titanium. There were a number of tests with delamination of the carbon fiber, and the best cutting parameters to minimize surface roughness and burr formation were tool cutting edge angle of 45º, a feed rate of 0.028 mm/tooth, cutting depth equal to 0.26 mm and cutting speed equal to 150 m/min.

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Section: Figure 3 Interactions Graphs Between the Factors Over Surfasupporting

confidence: 82%

Study of Surface Roughness and Burr Formation After Milling of Carbon Fiber/Titanium Stacks

2019

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“…The turning force 2 mainly comes from the following two aspects: first, the elastic and plastic deformation resistance 4 produced by the three deformation zones; second, the friction force between the chip, the workpiece, and the tool. The turning force F can be decomposed into three mutually perpendicular forces, as shown in Figure 1: the main turning force F c , whose direction is perpendicular to the base plane and in line with the cutting speed V c direction; the radial force F r , whose direction is perpendicular to the feed direction in the base plane; and the feed force F f , whose direction is parallel to the feed direction in the base plane.…”

Section: Turning Forcementioning

confidence: 99%

“…The prediction of static turning force mainly includes the finite element method, the analytical modeling method, and the empirical formula method. 1–4 These methods have their advantages in predicting the static turning force. But the premise of its prediction is to analyze the existing turning force data and get the corresponding model, so as to find out the relationship between turning force and some parameters.…”

Section: Introductionmentioning

confidence: 99%

Dynamic turning force prediction and feature parameters extraction of machine tool based on ARMA and HHT

Zhang

Zhao

2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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The dynamic prediction of turning force is an effective means to reflect the changing course and characteristics of the force in the whole cutting process. It is very important to model and predict the turning force and analyze its spectrum characteristics. In order to obtain the dynamic turning force, the circular cutting experiment of 12Cr18Ni9 rotary piece was carried out on the numerical control machine ETC1625P. The KISTLER sensor was mounted on the tool head of the machine tool, and the real-time turning forces in three cutting directions were measured. The experimental data show that the turning force fluctuates with the change of displacement in the feed direction. In order to study the complex nonlinear relationship between turning force and cutting parameters, the dynamic turning force was predicted by autoregressive-moving average modeling. The time–frequency analysis of the main turning force was carried out by using Hilbert–Huang transform. The local time–frequency characteristics of the signal were obtained by analyzing the Hilbert amplitude spectrum of the signal. When only one cutting parameter was changed, the maximum amplitude of Hilbert marginal spectrum of turning force signal changed with the change of cutting parameters. The results show that the high-precision modeling of dynamic turning force and the extraction of cutting features can be effectively realized by using autoregressive-moving average and Hilbert–Huang transform.

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“…Ultrasonic vibration machining technology can realize intermittent cutting. In the cutting process, it can effectively reduce the cutting force, reduce the cutting temperature, improve the stability of the machining process, increase the surface residual compressive stress, obtain more regular surface microstructure, and form excellent microstructure (nanocrystalline / ne-grained whole lamellar compact structure) on the surface layer [13][14][15][16][17][18], Widely used in machining di cult-to-machine materials [19,20].…”

Section: Introductionmentioning

confidence: 99%

Research on cutting force and surface integrity of TC18 titanium alloy by longitudinal ultrasonic vibration assisted milling

Xie

Wang

Liu

et al. 2022

Int J Adv Manuf Technol

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In order to study the in uence of rotational speed and amplitude on the surface integrity, TC18 titanium alloy samples were milled by the process of conventional milling and longitudinal ultrasonic vibration assisted milling. The experimental data were obtained by dynamometer, thermometer, scanning electron microscope, X-ray diffractometer and three-dimensional surface topography instrument for observation and analysis. The results show that the rotational speed has a signi cant effect on the cutting force, cutting temperature, surface morphology and surface residual stress. Compared with ordinary milling, the surface micro-texture produced by ultrasonic vibration milling is more regular, , and with the increase of rotational speed, the in uence of ultrasonic vibration on cutting force and cutting temperature decrease.There are adverse effects on surface roughness after ultrasonic vibration superposition. The in uence of ultrasonic vibration on the surface residual compressive stress is also greatly reduced when the rotational speed is greater than 2400 rpm. In addition, a certain depth of plastic deformation layer can be formed under the surface of ultrasonic vibration machining, and the depth of deformation layer increases with the increase of vibration.

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FEM to predict the effect of feed rate on surface roughness with cutting force during face milling of titanium alloy

Cited by 37 publications

References 10 publications

Study of Surface Roughness and Burr Formation After Milling of Carbon Fiber/Titanium Stacks

Study of Surface Roughness and Burr Formation After Milling of Carbon Fiber/Titanium Stacks

Dynamic turning force prediction and feature parameters extraction of machine tool based on ARMA and HHT

Research on cutting force and surface integrity of TC18 titanium alloy by longitudinal ultrasonic vibration assisted milling

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