Modeling and analyses of helical milling process

Tian, Yanling; Liu, Yunpeng; Wang, Fujun; Jing, Xiubing; Zhang, Dawei; Liu, Xianping

doi:10.1007/s00170-016-9418-2

Cited by 23 publications

(8 citation statements)

References 18 publications

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“…In this choice, factors such as cost and tool life must also be taken into account. Factors such as the greatest possible versatility of operations, the superior quality of machined surfaces, low cutting forces, and lower operating costs with advantages for productivity demonstrated by HM, appear as strong arguments for this process as an alternative to D. [47][48][49] Isbilir and Ghassemieh 50 developed a FE analysis for D operations in titanium alloys. Zhu et al 51 investigated dry D under different cutting parameters, it was possible to verify that for higher F there is an increase in thrust force, also F greatly influences the size and shape of chips, high V c and low F generates better surface quality than low V c and high F. Waqar et al 52 evaluated the effect of D parameters on hole quality in dry D and concluded that V c is directly responsible for surface quality and better surface finish are obtained with lower F and high V c .…”

Section: Methodsmentioning

confidence: 99%

Machining of titanium alloys for medical application - a review

Festas

Ramos

Davim

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Titanium alloys for their characteristics have acquired a prominent position in numerous industrial applications. Due to its properties, such as high resistance to corrosion, reduced density, high specific strength, and low Young’s modulus, titanium alloys became indispensable as a biomaterial with high use in medical devices, with special emphasis in the area of orthopedics. Problems associated with its manufacturing by conventional machining processes, such as milling, turning, and drilling are well known and studied. Its low thermal conductivity, high chemical reactivity, high hardness at high temperatures make it classified as difficult to machine material. Despite the already extensive knowledge about machining titanium alloys problems, and the constant technological development to overcome them, it is not yet possible to machine this material like other metals. This work is based on research and review papers from Scopus and Scholar from 2010 to 2020 and addresses the main issues related to the machining of titanium alloys used in medical devices manufacturing and current solutions adopted to solve them. From the research consulted it was possible to conclude that it is consensual that for milling, turning, and helical milling cutting speed can reach up to 100 m/min and up to 40 m/min in drilling. As for feed rate, up to 0.1 mm/tooth for milling and helical milling and up to 0.3 mm/rev for turning and 0.1 mm/rev for drilling. Also, that Minimum Quantity Lubrication is a valid and efficient solution to mitigate titanium alloys machining problems.

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Section: Methodsmentioning

confidence: 99%

Machining of titanium alloys for medical application - a review

Festas

Ramos

Davim

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Should also be considered in the process of choosing the most adequate method of hole making, the cost of the tools and the task execution time. The tools used in HM were almost 30% of the value of the drills used, with the advantage of flexibility in getting the desired dimension, as was stated by Ozturk et al [27] and Tian et al [21].…”

Section: Discussionmentioning

confidence: 90%

“…Brinksmeier et al [11], Denkena et al [20] and Tian et al [21] analyzed comprehensively the theoretical modelling of HM. In the HM process, the rotating tool, a mill with centre cutting, performs a circular motion in the plane XY simultaneously advancing in Z, thereby describing a vertical downward helical movement.…”

Section: Manufacturing Processesmentioning

confidence: 99%

A Study of the Effect of Conventional Drilling and Helical Milling in Surface Quality in Titanium Ti-6Al-4V and Ti-6AL-7Nb Alloys for Medical Applications

et al. 2020

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In the manufacturing of a medical device, may occur the need to make a hole with a specific function. Among current methods, conventional drilling (CD) referred in this work as drilling (D) and helical milling (HM) are two options with different potential.When making the hole, it is important to choose the most suitable method to obtain the desired geometry and ensure the functionality of the device. This work aims to analyze surface parameters as, arithmetic average height (R a ), the maximum height of the profile (R t ), the average peak to valley height (R z DIN), chip formation and the geometric deviation of holes obtained by the previously referred manufacturing processes. The specimens, with cylindrical geometry, were made of titanium alloys, Ti-6Al-4V and Ti-6Al-7Nb, currently used in the manufacture of medical devices. For this purpose, holes were made in a machining centre with different feed rate (F) for both methods and in the value of vertical step (a p ) in HM. The results obtained demonstrate that, at lower F and a p , HM presents better results. The Ti-6Al-7Nb alloy presents better roughness results compared to Ti-6Al-4V, validating it as a material able to be used in medical devices according to the fact that, a lower roughness is associated with higher corrosion resistance and fewer fatigue problems derived from it in components. By the work carried out, can be concluded that the roughness values obtained in HM are lower to those obtained by D making HM as a better option in hole making.

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“…The tooth trajectory is considered circular (cycloid effect neglected), according to Segonds et al [18]. But axial cutting depth b is different to the milling, because axial cutting depth b changes with the position of the side cutting edge [15,19]. As shown in Fig.…”

Section: Instantaneous Cutting Chip Analysis In Helical Millingmentioning

confidence: 99%

Modelling of cutting forces and researching calibration method in helical milling

Shang

Qin

et al. 2017

Int J Adv Manuf Technol

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Helical milling is a high efficiency, high quality hole-making technology, which enjoys very good usage prospects for the aeronautical and aerospace industry. In the helical milling process, the chip thickness is highly variable along the cutting edges and during the tool revolution due to the special cutting trajectory. The aim of this study is to develop a cutting force model and build a new calibration method of cutting force coefficients for helical milling. First, the tool motion of helical milling and the geometry of the chip are analyzed, and then the cutting force model is established. After that the calibration method of cutting force coefficients is built. In the end, a series of cutting experiments were conducted to validate the cutting force model and the calibration method. With this model, it is possible to analyze cutting forces and optimize the cutting parameters, and then get a better quality of hole-making.

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Modeling and analyses of helical milling process

Cited by 23 publications

References 18 publications

Machining of titanium alloys for medical application - a review

Machining of titanium alloys for medical application - a review

A Study of the Effect of Conventional Drilling and Helical Milling in Surface Quality in Titanium Ti-6Al-4V and Ti-6AL-7Nb Alloys for Medical Applications

Modelling of cutting forces and researching calibration method in helical milling

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