Optimization of Cutting Data and Tool Inclination Angles During Hard Milling with CBN Tools, Based on Force Predictions and Surface Roughness Measurements

Matras, Andrzej; Zębala, Wojciech

doi:10.3390/ma13051109

Cited by 12 publications

(7 citation statements)

References 30 publications

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“…Correct machining parameters have a significant impact on machining stability and thus on the quality of the processed surface [3]. In addition, tool life is extended, which directly reduces machining costs [19].…”

Section: Resultsmentioning

confidence: 99%

“…To obtain a high surface quality should be optimized determination of cutting parameters. Manufacturers of tools give ranges of recommended parameters, but in order to achieve the best possible surface area is necessary to define the exact parameters [3]. One of the criteria for ensuring high surface quality is reducing the tool vibration [4].…”

Section: Introductionmentioning

confidence: 99%

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The Possibility of Applying Acoustic Emission Method to Optimize Determination of Milling Parameters

Dudzik

2020

Wseas Transactions on Systems and Control

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Nowadays acoustic emission (AE) method is used in many fields of science, including in thediagnosis and monitoring of machining processes such as turning, grinding, milling, etc. Monitoring of millingprocess allows to ensure stable conditions of treatment. Stable conditions of milling process have a great impacton the quality of the surface. There are different methods used for monitoring machining processes, i.e.dynamometer methods, thermography, vibrations measurement, acoustic emission, etc. The research wascarried out on a universal FUW3157 III milling machine using end mills made of HSS. Tools were in differentstages of wear. The research was carried out at constant rotational speed and variable other cutting parameters,i.e. feed, depth of cut. Milling process was performed on a sheet made of EN AW-7020 aluminium alloy. Themilling process was monitored by an acoustic emission set made by Physical Acoustics Corporation (PAC).The PAC system consists of: preamplifier USB AE Node, type 1283 with bandpass 20 kHz – 1 MHz, AE signalmeasurement sensor type VS 150M, with a frequency range 100 – 450 kHz, computer with AE Win for USBVersion E5.30 software for recording and analysing AE data. During the study, the acoustic emission signalsgenerated during milling process were recorded and then chosen parameters were analyzed e. g.: amplitude,number of events - hits, the effective value of the signal (RMS). The study can be the basis for the use ofacoustic emission method for monitoring milling process and determining the parameters to ensure stableconditions of that process and the same to obtain a high quality surface

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

The Possibility of Applying Acoustic Emission Method to Optimize Determination of Milling Parameters

Dudzik

2020

Wseas Transactions on Systems and Control

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“…Matras [19] addressed machining of hardened steel with a CBN ball mill. He proposed a cutting force prediction algorithm that takes into account the tool contact point at a speci c location of the shaped workpiece during three-axis milling.…”

Section: Introductionmentioning

confidence: 99%

Identifying the lead angle limit to achieve required surface roughness in ball-end milling

Pesice

Vavruska²,

Falta³

et al. 2022

Preprint

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When milling generally-shaped surfaces with a ball-end milling tool, machined surface roughness and accuracy as well as machining productivity are often monitored. Improving one of these parameters often causes a decrease in the other monitored parameters. Therefore, knowing possible ways of influencing these parameters is important for achieving the optimum result, if possible, in all requirements. A deep understanding of how some technological parameters influence finished surface roughness is still lacking, as well as detailed knowledge of the relationships among some roughness parameters. In response, an experiment entailing machining of planar samples at different orientation angles was carried out to identify the influence of the studied parameters on the transverse roughness of the final surface. A finding was made, that the resulting surface roughness is dependent on the cutting edge geometry of the particular ball-end milling tools used and the achieving of the required surface roughness can be guaranteed by setting the specific lead angles. Furthermore, it was verified that a minimum lead angle limit can be found based on the geometric properties of the specific milling tool, and the relationship between the evaluated roughness parameters Ra and Rz was found as well.

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“…According to this model, the surface inclination has a significant effect. Matras and Zębala [8] optimized the cutting data and tool path pattern for machining the freeform surface of steel in a hardened state using a ball-end mill. The results show that the surface roughness and cutting-force components can be controlled by modifying the feed rate based on the locally machined cross-sectional area.…”

Section: Introductionmentioning

confidence: 99%

The Effect of the Cutting Speed on the Surface Roughness When Ball-End Milling

Mgherony¹,

Mikó²

2021

Hung. J. Ind. Chem.

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Using freeform surfaces in advanced industries is becoming ubiquitous and widely applied in many fields such as the aerospace, automobile, consumer products as well as the die and mold industries. The ball-end mill is mainly used in machining such surfaces. However, the manufacture of this type of surface is still somewhat difficult when machining using a 3D ball-end milling machine. Due to changes in the surface inclination, the working diameter of the tool also changes. Variations in the working diameter leads to an unstable cutting speed, affecting the roughness homogeneity of the smoothed surface. This article discusses the effect of changing the cutting speed on the surface roughness in the case of concave and convex surfaces.

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Optimization of Cutting Data and Tool Inclination Angles During Hard Milling with CBN Tools, Based on Force Predictions and Surface Roughness Measurements

Cited by 12 publications

References 30 publications

The Possibility of Applying Acoustic Emission Method to Optimize Determination of Milling Parameters

The Possibility of Applying Acoustic Emission Method to Optimize Determination of Milling Parameters

Identifying the lead angle limit to achieve required surface roughness in ball-end milling

The Effect of the Cutting Speed on the Surface Roughness When Ball-End Milling

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