Models for Prediction of Surface Roughness in a Face Milling Process Using Triangular Inserts

Wang, Rui; Wang, Bingxu; Barber, Gary C.; Gu, Jie; Schall, J. David

doi:10.3390/lubricants7010009

Cited by 20 publications

(17 citation statements)

References 17 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…Often, the surface roughness of a mechanical component determines its functionality in the range of its intended use [ 25 , 26 ]. The values of surface roughness parameters mainly depend on the cutting process parameters [ 27 ] and the cutting edge geometry, which is taken into account by models predicting the values of these parameters [ 28 , 29 , 30 ]. The surface roughness also depends on the relative position of the face milling tool towards the workpiece [ 31 ].…”

Section: Introductionmentioning

confidence: 99%

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

et al. 2021

View full text Add to dashboard Cite

Lightweight alloys made from aluminium are used to manufacture cars, trains and planes. The main parts most often manufactured from thin sheets requiring the use of milling in the manufacturing process are front panels for control systems, housing parts for electrical and electronic components. As a result of the final phase of the manufacturing process, cold rolling, residual stresses remain in the surface layers, which can influence the cutting processes carried out on these materials. The main aim of this study was to verify whether the strategy of removing the outer material layers of aluminium alloy sheets affects the surface roughness after the face milling process. EN AW-6082-T6 aluminium alloy thin plates with three different thicknesses and with two directions relative to the cold rolling process direction (longitudinal and transverse) were analysed. Three different strategies for removing the outer layers of the material by face milling were considered. Noticeable differences in surface roughness 2D and 3D parameters were found among all machining strategies and for both rolling directions, but these differences were not statistically significant. The lowest values of Ra = 0.34 µm were measured for the S#3 strategy, which asymmetrically removed material from both sides of the plate (main and back), for an 8-mm-thick plate in the transverse rolling direction. The highest values of Ra = 0.48 µm were measured for a 6-mm-thick plate milled with the S#2 strategy, which symmetrically removed material from both sides of the plate, in the longitudinal rolling direction. However, the position of the face cutter axis during the machining process was observed to have a significant effect on the surface roughness. A higher surface roughness was measured in the areas of the tool point transition from the up-milling direction to the down-milling direction (tool axis path) for all analysed strategies (Ra = 0.63–0.68 µm). The best values were obtained for the up-milling direction, but in the area of the smooth execution of the process (Ra = 0.26–0.29 µm), not in the area of the blade entry into the material. A similar relationship was obtained for analysed medians of the arithmetic mean height (Sa) and the root-mean-square height (Sq). However, in the case of the S#3 strategy, the spreads of results were the lowest.

show abstract

Section: Introductionmentioning

confidence: 99%

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

et al. 2021

View full text Add to dashboard Cite

show abstract

“…Both roughness curves increased gradually with the increase of axial DOC. According to the proposed surface roughness model in the milling process [22], axial DOC is not the main factor influencing the surface roughness. This may be attributed to the fact that micro milling in high axial DOC conditions could generate high milling force and high deformation, which deteriorates the surface quality.…”

Section: Surface Roughnessmentioning

confidence: 99%

Experimental Study on Machinability of Zr-Based Bulk Metallic Glass during Micro Milling

Wang

Zhang

et al. 2020

Micromachines

View full text Add to dashboard Cite

The micro machinability of Zr41.2Ti13.8Cu12.5Ni10Be22.5 bulk metallic glass (BMG) was investigated by micro milling with coated cemented carbide tools. The corresponding micro milling tests on Al6061 were conducted for comparison. The results showed that the tool was still in stable wear stage after milling 300 mm, and the surface roughness Ra could be maintained around 0.06 μm. The tool experienced only slight chipping and rubbing wear after milling the BMG, while a built-up edge and the coating peeling off occurred severely when milling Al6061. The influence of rotation speed on surface roughness was insignificant, while surface roughness decreased with the reduction of feed rate, and then increased dramatically when the feed rate was below 2 μm/tooth. The surface roughness increased gradually with the axial depth of cut (DOC). Milling force decreased slightly with the increase in rotation speed, while it increased with the increase in axial DOC, and the size effect on milling force occurred when the feed rate decreased below 1 μm/tooth. The results of X-ray diffraction (XRD) showed that all milled surfaces were still dominated by an amorphous structure. This study could pave a solid foundation for structural and functional applications.

show abstract

“…In the first direction, the tool wear and other machining characteristics were modeled depending on the physical, chemical, and geometrical phenomena such as friction, temperature, cutting, Etc. [8,9]. This approach is quite difficult to perform because many factors that influence on the wear of tool and other output parameters.…”

Section: Introductionmentioning

confidence: 99%

A Study on the Tool Wear in Milling Process of the Gleason Spiral Bevel Gear

Thinh¹,

Dong²,

Quoc³

2020

Adv. sci. technol. eng. syst. j.

View full text Add to dashboard Cite

Models for Prediction of Surface Roughness in a Face Milling Process Using Triangular Inserts

Cited by 20 publications

References 17 publications

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

Experimental Study on Machinability of Zr-Based Bulk Metallic Glass during Micro Milling

A Study on the Tool Wear in Milling Process of the Gleason Spiral Bevel Gear

Contact Info

Product

Resources

About