Investigating effects of milling conditions on cutting temperatures through analytical and experimental methods

Karagüzel, Umut; Budak, Erhan

doi:10.1016/j.jmatprotec.2018.07.024

Cited by 36 publications

(11 citation statements)

References 27 publications

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“…Cui [17] and De-Buruaga [18] focused on how the chip formed and the problem of end milling temperatures. Other relevant research belongs to Möhring [19], Karaguzel [20], and Xie [21], who studied the effects of changing the geometric parameters of the tool on the formation of the chip and on the whole cutting process. The analysis of the chip formation process showed that the thickness of the non-detached chip also varies depending on the angle of inclination of the cutting tool, and the use of 3D models to analyze the chip formation process shows this fact.…”

Section: Introductionmentioning

confidence: 99%

Study about the chip formation in the turning process using the finite element analysis

Pop

Țîțu

2022

IOP Conf. Ser.: Mater. Sci. Eng.

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At this time, there is a significant interest in the chip shape and formation at the international level, an issue studied based on mathematical calculations, experiments, and finite element analysis. The analysis of the chip formation process showed that the thickness of the undetached chip also varies according to the rake angle of the cutting tool, and using 3D models to analyze the chip formation process demonstrates this fact. Following the research, a study was conducted in which an analysis of the chip morphology is presented. Using Deform 2D application, a finite element simulation - a comparative analysis of the chip formation was performed when the value of the clearance angle varies. The increasing variety of cutting radius values has an influence on the way the chips are formed in terms of thickness, which generate differences in its shape. Following the study, a series of conclusions and own findings emerged that with the increase of the cutting-edge radius, the stress distribution is radial over a greater area of the part, reason for which the deformation of the chip is smaller. Arguments have also been made on distribution of the temperature, which is directly influenced by the shape of the tool, influencing the temperature of the generated chip. The results also show that with the increase of the cutting-edge radius of the tool, there is a tendency for the detached chip to settle.

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Section: Introductionmentioning

confidence: 99%

Study about the chip formation in the turning process using the finite element analysis

Pop

Țîțu

2022

IOP Conf. Ser.: Mater. Sci. Eng.

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“…On the other hand, in terms of cutting technology, there are respectively: peripheral milling, end milling, and face milling. The selection of a proper milling variant has a significant impact on the cutting forces [ 2 ], temperature [ 3 , 4 ], the dynamics of the milling process, chip formation, as well as the quality of a surface after milling [ 5 , 6 , 7 ]. Figure 1 presents the types of milling along with the direction of a resultant cutting force.…”

Section: Introductionmentioning

confidence: 99%

High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude

et al. 2021

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High feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the high feed milling (HFM), experimental tests were conducted, preceded by an analysis of cutting zones when milling with an HF face cutter. The face milling tests of 42CrMo4 steel with the use of an HF cutter characterized by an entering angle, dependent on axial depth of cut ap and insert radius r values, as well as with a conventional face cutter with the entering angle of 45° were performed. The study focused on analyzing the vibration amplitude, cutting force components in the workpiece coordinate system, and surface roughness. The experimental tests proved, that when milling with constant cut layer thickness, the high feed cutter allowed to obtain twice the cutting volume in comparison with the conventional face cutter. However, higher machining efficiency resulted in an increase in cutting force components. Furthermore, the results indicate significantly higher surface roughness and higher vibration amplitudes when milling with the HF cutter.

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“…All the above-mentioned studies did not include temperature as a consideration. Temperature of workpiece is related to flank wear, and multiple studies had devoted to measurement of temperature [27], and effect of temperature on workpiece [28]. In aeronautics, brass materials, like H62 brass, are often components of valve.…”

Section: Introductionmentioning

confidence: 99%

Corner-milling process parameter optimization regarding H62 brass using Kriging model and improved particle swarm optimization algorithm

Meng

Wang

Liao

et al. 2020

J Braz. Soc. Mech. Sci. Eng.

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Single-pass corner milling is common in machining process. Machining quality and cost are the two most important goals for machining process. Machining quality is greatly affected by deformation and mechanical property. Cutting temperature has a very important effect on tool wear, mechanical property, deformation and machining precision. In this paper, cost per volume (CPV) and machining temperature are selected as objectives. To reduce the cost of research, AdvantEdge simulation software was used to simulating the machining process and examined for its accuracy. Comparing the result of AdvantEdge with physical experiments, it showed an average 8% error on CPV and a 6% error on temperature. Given this comparison, simulation data were used to train Kriging model as the surrogate model. Kriging model manifested high accuracy, showing mean error of 6% and 3% in terms of CPV and temperature on validation points. To solve the multi-objective problem, a K-means particle swarm optimization (PSO) was constructed, which outperformed traditional adaptive gird algor (AGA) by finding the better optimal solutions, meanwhile consuming lesser time. Optimization result showed that corner milling should have a low-level spindle speed to ensure low cost and low temperature. High feed rate, cutting depth and cutting width will result in low cost along with high temperature. Optimal parameters should be chosen from Pareto set according to different practical needs. This integrated method manifested its applicability in solving multi-objective problems.

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Investigating effects of milling conditions on cutting temperatures through analytical and experimental methods

Cited by 36 publications

References 27 publications

Study about the chip formation in the turning process using the finite element analysis

Study about the chip formation in the turning process using the finite element analysis

High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude

Corner-milling process parameter optimization regarding H62 brass using Kriging model and improved particle swarm optimization algorithm

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