Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

Laamouri, Adnen; Ghanem, Farhat; Braham, C.; Sidhom, Habib

doi:10.1007/s00170-019-04280-2

Cited by 22 publications

(17 citation statements)

References 53 publications

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“…On the contrary, the surface residual stress and its influence layer depth under horizontal upward were deeper than horizontal upward. It is commonly known that surface integrity plays an important role in fatigue life, so Laamouri et al 25 evaluated the influence of the milling path on surface integrity and fatigue strength of X160CrMoV12. The surface showed tensile residual stress, and metal wrinkles and short microcracks occurred in up milling.…”

Section: Introductionmentioning

confidence: 99%

Effects of cutter path orientations on milling force, temperature, and surface integrity when ball end milling of TC17 alloy

Shen

Zhang

Tan

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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To explore the effects of cutter path orientations on milling force, temperature, and surface integrity, end ball milling experiments of TC17 titanium alloy were accomplished derived from different cutter path orientations. The experiment results of milling force and temperature were obtained. Combining with the thermo-mechanical coupling, this paper analyzes the impact of the cutter path orientations on the surface roughness, surface topography, in-depth residual stress, microhardness distributions, and microstructure. The results indicate that the maximum milling force is 224.24 N and the temperature is 672°C under vertical downward milling path, while horizontal downward orientation provides the lowest cutting force of 81.12 N and temperature of 493°C. The surface topography of the four cutter path orientations is basin-like shape, and the minimum surface roughness of 1.128 µm is achieved under vertical upward mode. Moreover, the maximum compressive residual stress of −491.8 MPa and the maximum residual stress layer depth of 45 µm are acquired under vertical downward milling. The maximum microhardness can arrive at 390 HV0.025 under the vertical path. Additionally, the transformation of the material microstructure remains elongated, bent, and fractured. The maximum plastic deformation layer depth is 44 µm under vertical downward milling path.

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Section: Introductionmentioning

confidence: 99%

Effects of cutter path orientations on milling force, temperature, and surface integrity when ball end milling of TC17 alloy

Shen

Zhang

Tan

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…The adhesion is believed to compromise the true geometry and sharpness of the cutting edge, thus leading to generation of a rougher surface. The superiority of down-milling regarding work surface finish was also reported for the milling of a tool steel [26]. It is quite surprising to see micro-lubrication yielding better surface finish than the two cryogenic coolants.…”

Section: Work Surface Roughnessmentioning

confidence: 64%

“…Mia et al reported that the use of dual jets of LN 2 is an excellent way to reduce energy consumption and working temperature, as well as to improve work surface quality [15]. In another experimental study, it was reported that the use of liquid CO 2 at a temperature of −79.5 • C in cutting of a nickel-chromium alloy could reduce average surface roughness by [42][43][44][45][46][47][24][25][26][27][16][17][18][19][20][21] wet, and MQL cutting, respectively [16]. Furthermore, the cryogenic cooling was also found to increase the compressive stresses on the surface and decrease the flank wear.…”

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confidence: 99%

“…A tool orientation optimization model was presented that includes the effect of deflection error caused by milling forces to achieve better machining precision controlling in five-axis surface milling [25]. The effects of up-and down-milling were compared in peripheral milling of a high-alloy steel [26]. The up-milling approach was found to generate compressive residual stresses in the work surface, but with a poor surface finish in comparison with down-milling.…”

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confidence: 99%

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Sustainable Milling of Ti-6Al-4V: Investigating the Effects of Milling Orientation, Cutter′s Helix Angle, and Type of Cryogenic Coolant

Iqbal

Suhaimi

Zhao

et al. 2020

Metals

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Ti-6Al-4V, the most commonly used alloy of titanium, possesses excellent mechanical properties and corrosion resistance, which is the prime reason for the continual rise in its industrial demand worldwide. The extraordinary mechanical properties of the alloy are viewed as a hindrance when it comes to its shaping processes, and the process of milling is no exception to it. The generation of intense heat flux around the cutting zones is an established reason of poor machinability of the alloy and unacceptably low sustainability of its machining. The work presented in this paper attempts to enhance sustainability of milling Ti-6Al-4V by investigating the effects of milling orientation, cutter's helix angle, cutting speed, and the type of cryogenic coolant and lubricant on the sustainability measures, such as tool damage, cutting energy consumption, process cost, milling forces, and work surface roughness. It was found that micro-lubrication is more effective than the two commonly used cryogenic coolants (carbon dioxide snow and liquid nitrogen) in reducing tool wear, work surface roughness, process cost, and energy consumption. Furthermore, down-milling enormously outperformed up-milling with respect to tool wear, work surface quality, and process cost. Likewise, the high levels of cutter's helix angle and cutting speed also proved to be beneficial for milling sustainability.Metals 2020, 10, 258 2 of 25 environmentally [3]. The problem is generally negotiated either by lowering the material removal rates or by applying emulsion-based coolants, neither of which actually offers a sustainable solution.With regard to quashing the intense heat flux around the cutting areas, the application of cryogenic fluids, especially liquid nitrogen (LN 2 ), fares very well. The fluids offer a viable solution because of extremely low operational temperatures, no waste generation, and controllable flow rates. Additionally, application of micro-lubrication, also known as minimum quantity of lubrication (MQL), also proved to be very beneficial in enhancing tool life and improving surface quality in machining of titanium alloys conducted at medium cutting speeds [4,5]. MQL is a near-dry machining method in which a miniscule quantity of lubricating oil is pulverized into a stream of air, and the resulting aerosol is applied onto the cutting areas [6].Although steady progress is being made regarding quantification of the effects of cryogenic coolants with regard to the continuous machining processes, not much effort is being put up concerning interrupted machining processes, such as milling. Cryogenic milling is distinct from continuous machining processes performed under cryogenic environment in the sense that the cutting teeth of a milling tool periodically and rapidly engage and disengage with the work material, leading to cyclic heating (caused by thermal energy released by work material's plastic deformation) and cooling (caused by interaction with the incoming cryogenic fluid) of the cutting edges. Such a course is expected to induce...

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“…Further improvements in the mechanical properties of the SRM with CCC by adding fillers or reinforcing additives, such as wollastonite, glass fibers, carbon fibers, glass sphere, molybdenum disulfide [ 66 , 67 , 68 , 69 ], zirconia [ 70 , 71 , 72 ], silica sand, or silicon nitride [ 73 , 74 , 75 ] into the SRB is also an important research issue. In addition, the internal surface of CCC has high surface roughness [ 76 , 77 , 78 ] and result in reduction in mold life due to stress concentration [ 79 , 80 , 81 , 82 ]. Thus, surface improvement of the CCC by abrasive flow machining [ 83 ], electrochemical polishing [ 84 ], chemical polishing [ 85 ], laser polishing [ 86 ], ultrasonic cavitation abrasive finishing [ 87 ], or abrasive blasting [ 88 ] is also an important research topic.…”

Section: Resultsmentioning

confidence: 99%

Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

Kuo

2021

Polymers

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Silicone rubber mold (SRM) is capable of reducing the cost and time in a new product development phase and has many applications for the pilot runs. Unfortunately, the SRM after injection molding has a poor cooling efficiency due to its low thermal conductivity. To improve the cooling efficiency, the thermal conductivity of the SRM was improved by adding fillers into the SRM. An optimal recipe for fabricating a high cooling efficiency low-pressure injection mold with conformal cooling channel fabricated by fused deposition modeling technology was proposed and implemented. This study proposes a recipe combining 52.6 wt.% aluminum powder, 5.3 wt.% graphite powder, and 42.1 wt.% liquid silicon rubber can be used to make SRM with excellent cooling efficiency. The price–performance ratio of this SRM made by the proposed recipe is around 55. The thermal conductivity of the SRM made by the proposed recipe can be increased by up to 77.6% compared with convention SRM. In addition, the actual cooling time of the injection molded product can be shortened up to 69.1% compared with the conventional SRM. The actual cooling time obtained by the experiment is in good agreement with the simulation results with the relative error rate about 20%.

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Influences of up-milling and down-milling on surface integrity and fatigue strength of X160CrMoV12 steel

Cited by 22 publications

References 53 publications

Effects of cutter path orientations on milling force, temperature, and surface integrity when ball end milling of TC17 alloy

Effects of cutter path orientations on milling force, temperature, and surface integrity when ball end milling of TC17 alloy

Sustainable Milling of Ti-6Al-4V: Investigating the Effects of Milling Orientation, Cutter′s Helix Angle, and Type of Cryogenic Coolant

Improving Cooling Performance of Injection Molding Tool with Conformal Cooling Channel by Adding Hybrid Fillers

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