Influence of micro-structured milling cutter on the milling load and surface roughness of 6061 aluminum alloy

Pan, Jianfeng; Ni, Jing; He, Lihua; Cui, Zhi; Feng, Kai

doi:10.1007/s00170-020-06080-5

Cited by 14 publications

(6 citation statements)

References 26 publications

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“…Carbide tools are used for rapid hole drilling due to their prolonged life compared to tools made from high-speed steel and higher hardness [7,8]. The microstructure of the cutting tool was previously reported to influence the machined part's surface finish and cutting forces when machining Al6061 alloy [9]. Coolants can be an excellent choice to improve part finish when machining light alloys and to prolong tool life [10,11], but this is not always possible, depending on the final part requirements.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Al-Tameemi

Al-Dulaimi

Awe³

et al. 2021

Materials

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Aluminum alloys are soft and have low melting temperatures; therefore, machining them often results in cut material fusing to the cutting tool due to heat and friction, and thus lowering the hole quality. A good practice is to use coated cutting tools to overcome such issues and maintain good hole quality. Therefore, the current study investigates the effect of cutting parameters (spindle speed and feed rate) and three types of cutting-tool coating (TiN/TiAlN, TiAlN, and TiN) on the surface finish, form, and dimensional tolerances of holes drilled in Al6061-T651 alloy. The study employed statistical design of experiments and ANOVA (analysis of variance) to evaluate the contribution of each of the input parameters on the measured hole-quality outputs (surface-roughness metrics Ra and Rz, hole size, circularity, perpendicularity, and cylindricity). The highest surface roughness occurred when using TiN-coated tools. All holes in this study were oversized regardless of the tool coating or cutting parameters used. TiN tools, which have a lower coating hardness, gave lower hole circularity at the entry and higher cylindricity, while TiN/TiAlN and TiAlN seemed to be more effective in reducing hole particularity when drilling at higher spindle speeds. Finally, optical microscopes revealed that a built-up edge and adhesions were most likely to form on TiN-coated tools due to TiN’s chemical affinity and low oxidation temperature compared to the TiN/TiAlN and TiAlN coatings.

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Section: Introductionmentioning

confidence: 99%

Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Al-Tameemi

Al-Dulaimi

Awe³

et al. 2021

Materials

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“…J. Pan constructed linear flute and V-groove micro-texture structures on the tool surface and conducted milling tests. It was found that the V-groove micro-texture tool promoted the milling three-way force reduction by 9.27%, 21.98%, and 12.44%, respectively, and in addition, it was also found that the V-groove micro-texture tool improved the surface finish of the machined workpiece [12]. X. Tong calculated the theoretical tool-chip contact length during cutting based on the chip curl theory and combined it with the metal cutting theory and the mechanism of micro-texture action to obtain the theoretical tool-chip contact area, which provides a theoretical basis for the subsequent precise preparation of microtexture on the tool surface [13].…”

Section: Introductionmentioning

confidence: 89%

Influence of Lubrication Status on Milling Performance of Bionic Micro-Textured Tools

Shi,

Ma,

Wang

et al. 2024

Lubricants

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Titanium alloy material has physical properties such as low thermal conductivity, high hardness, and surface resilience, which are prone to problems such as large milling force, low machining efficiency, and poor surface quality in processed products during dry milling. This document details our process of isolating micro-textures from biological structures, applying them to cutting tool surfaces to create micro-texture milling cutters, and employing this micro-texture technique to reduce friction and prevent wear on these cutters. According to the milling dosage and the installation position between the tool and the workpiece, the effective working area of the cutting edge of the ball-end milling cutter is calculated. At the same time, a self-lubricating cutter was constructed by using a laser to process micro-textures and filling solid lubricant inside the micro-textures. An analysis was conducted to compare the milling efficiency of bionic microtextured cutters in both dry and micro-lubricated environments. It was found that the self-lubricating tool promoted a 3% to 5% decrease in milling force, a reduction in the coefficient of friction, a high surface finish of the machined workpiece, and an alleviation of chip sticking at the edge area.

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“…Milling is a process in which a milling cutter with one or more teeth makes cuts with intermittent motion. Typically, a complete milling motion consists of a rotary motion of the milling cutter blade and shank being held on a spindle, with a feed motion of the workpiece in a fixture [26,27]. During the milling motion, the spindle speed at the tip position of the ball end milling cutter is constant at zero, which very easily causes wear on the milling cutter, affecting the machining quality of the product.…”

Section: Carbide Ball End Milling Cutter Micro-groove Distribution Lo...mentioning

confidence: 99%

Research on the Milling Performance of Micro-Groove Ball End Mills for Titanium Alloys

Zhang,

Shi,

Wang

et al. 2024

Lubricants

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Titanium alloys are widely used in various fields, but milling titanium alloy materials often leads to problems such as high milling forces, increased milling temperatures, and chip adhesion. Thus, the machinability of titanium alloys faces challenges. To improve the milling performance of titanium alloy materials, this study analyzes the effective working area on the surface of the milling cutter through mathematical calculations. We design micro-grooves in this area to utilize their friction-reducing and wear-resisting properties to alleviate the aforementioned issues. The effective working area of the ball end milling cutter’s cutting edge is calculated based on the amount of milling and the installation position between the milling cutter and the workpiece. By observing the surface structure of seashells, micro-grooves are proposed and designed to be applied in the working area of the milling cutter surface. The impact of the micro-groove area on the milling cutter surface and spindle speed on milling performance is discussed based on milling simulation and experimental tests. Experimental results show that the cutting force, milling temperature, and chip resistance to adhesion produced by micro-groove milling cutters are superior to conventional milling cutters. Milling cutters with three micro-grooves perform best at different spindle speeds. This is because the presence of micro-grooves on the surface of the milling cutter improves the friction state, promoting a reduction in milling force, while the micro-grooves also serve as storage containers for chips, alleviating the phenomenon of chip softening and adhesion to the cutter. When conducting cutting tests with a milling cutter that has three micro-grooves, the milling force is reduced by 10% to 30%, the milling temperature drops by 10% to 20%, and the surface roughness decreases by 8% to 12%.

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Influence of micro-structured milling cutter on the milling load and surface roughness of 6061 aluminum alloy

Cited by 14 publications

References 26 publications

Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Evaluation of Cutting-Tool Coating on the Surface Roughness and Hole Dimensional Tolerances during Drilling of Al6061-T651 Alloy

Influence of Lubrication Status on Milling Performance of Bionic Micro-Textured Tools

Research on the Milling Performance of Micro-Groove Ball End Mills for Titanium Alloys

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