Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Abstract

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

Trochoidal Milling Path with Variable Feed. Application to the Machining of a Ti-6Al-4V Part

“…The milled part has concave and convex walls. While the values of the radius of these walls are not constant, this situation is closer to reality and can be consider a novelty compared to previous tests with trochoidal milling [24][25][26][27]. The point with coordinates (x i , y i ) belongs to the arch of one of the trochoidal steps (Figure 15).…”

Analysis of Roughness Parameters Determining Tribological Properties in Hard Turned Surfaces

“…a burnished surface, means a better fluid-retention capacity comparative to the positive values of highly peaky surfaces. In the case of a zero or negative Ssk value, the load-bearing area of the surface is greater, therefore, its wear resistance is also greater [3]. This effect is enhanced by an Sku of 3 or lower, which is indicative of a relatively filled surface [19].…”

“…Many machined surfaces incorporate working surfaces, which move relative to other surfaces. The analysis and development of such surfaces is important because the surface quality [1,2] and, within this parameter, the topographical characteristics [3,4] by and large determine the lifetime of parts [5][6][7]. The characterization of surface topography is highlighted in the automotive industry, that is, predicting the values of roughness parameters [8] and the effect of technological data on the topography are determining factors in the design of machined parts [9].…”

Influence of cutting parameters on surface topography in high-speed milling of slots in titanium alloy TC4

“…Demand for efficient manufacturing processes with the capability to create high-quality parts from titanium alloys has driven the development of specialized tools, process parameters and machining strategies [3]. General guidelines for appropriate parameter selection in manufacturing processes are being widely researched including tool life prediction [4], influence of coatings on tool life and product quality [2,5].…”