Optimizing the micro-texture and cutting parameters of ball-end milling cutters to achieve milling stability

Tong, Xin; Qu, Qiang

doi:10.1177/09544089221104073

Cited by 7 publications

(4 citation statements)

References 9 publications

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“…Cutting parameters can affect the tool workpiece contact relationship and chip removal, ultimately affecting the stability of the milling system and the machining quality of the workpiece. In order to ensure the performance of ball-end milling cutters, with reference to the CNC tool selection guide and the team's previous research results [23,24], the axial cutting depth range is set to [0.3, 0.5 mm], the feed rate range is [0.06, 1 mm/r], and the cutting speed is [120, 160 m/min]. Due to the characteristic of "balanced dispersion, orderliness and comparability" in orthogonal tables, a few representative experimental conditions can be selected within the inspection range to achieve balanced sampling [25].…”

Section: Methodsmentioning

confidence: 99%

Uniform-Density Micro-Textured Ball-End Milling Cutter Model Based on Fractal and Uniform Distribution Theory

et al. 2023

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At present, for micro-textured tools, the determination of the micro-texture placement area depends on the derivation of the cutting geometric model. The micro-texture distribution form applies geometric methods, and the research methods and accuracy are limited. Therefore, in this paper, the ball-end milling cutter is taken as the research object. Based on fractal theory, the morphology of the tool before and after wear is compared to determine the tool–chip contact area. The uniform-density micro-texture distribution model is established using the uniform distribution point theorem, and the synergistic mechanism of the edge and the micro-texture is revealed. The strength of the micro-textured tool with uniform density under the action of the edge is studied by simulation. Finally, the determination of the tool–chip contact area and the establishment of a uniform-density micro-texture model is realized. It is proved that the synergistic effect of the cutting edge and the micro-texture has a positive effect on the milling behavior of the tool. When comparing the non-edge and non-texture tools with the cutting-edge tools, the maximum strain and stress of the cutting-edge micro-textured tools increased by 12% and 30%, and 30% and 20%, respectively, without affecting the normal use of the tool. This research provides a new method for the design of micro-textured tools.

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Section: Methodsmentioning

confidence: 99%

Uniform-Density Micro-Textured Ball-End Milling Cutter Model Based on Fractal and Uniform Distribution Theory

et al. 2023

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“…The range of values for the weights and factors (a, b, c, d, e, and f) is typically between 0 and 1. When a dragonfly individual has neighboring individuals around it, the position is updated using formula (20). When there are no neighboring individuals around the dragonfly individual, it randomly flies around the search space using Levy flight, and the update formula is shown in Equation ( 21):…”

Section: Multi Objective Optimization Based On the Moda Algorithmmentioning

confidence: 99%

“…In surface texture parameters optimization problems involving multiple contradictory performance indices, single-objective optimization often falls short in achieving superior overall performance, as enhancing one aspect may compromise another. Therefore, scholars address this challenge through multi-objective optimization [17][18][19][20]. Shinde [21] et al studied the influence of groove texture parameters (including position, height, width, number and spacing) on bearing performance, and used the gray correlation method to find an optimal set of parameter combinations to achieve maximum loading capacity and minimal friction torque.…”

Section: Introductionmentioning

confidence: 99%

Effect and optimization of triangular textures on lubrication performance of the thrust bearing

Yu,

Shi,

Jiang

et al. 2024

Preprint

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To enhance the loading capacity of the oil film and reduce its temperature, this article establishes a thrust bearing model with a triangular texture based on the modified Reynolds equation. The focus is on investigating the influence of texture parameters on both the temperature and pressure fields of the oil film. For the purpose of determining the parameter combination under the best lubrication performance, the improved multi-objective dragonfly algorithm (MODA) based on BP neural network is employed to optimize the temperature and loading capacity of oil film. The investigation revealed that the optimal lubrication performance is achieved with a texture width of approximately 0.23 mm, a texture depth of 0.5 mm, a texture number of 32 and a texture spacing of 5 mm. Under these conditions, when compared with a thrust bearing without texture, the textured thrust bearing increases its loading capacity by approximately 29% and reduces temperature by approximately 1.75 ºC.

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“…It was found that, compared with a pure-coated tool, the addition of micro-texture made the tool performance better, while a micro-pittexturecoated tool was better than a micro-groove-coated tool in terms of cutting force, white layer thickness and friction coefficient. Tong X [12] designed an orthogonal dry-cutting test, established a micro-texture distribution model under different cutting depths, studied the influence of micro-texture parameters on tool milling performance under variable cutting parameters, and optimized the combination of texture parameters according to different evaluation indexes. To explore the role of micro-textured tools with different shapes in the process of cutting titanium alloys, Wang Liang [13] selected several microtextures with different shapes and designed experiments with cutting parameters and micro-texture parameters as changing factors.…”

Section: Introductionmentioning

confidence: 99%

Study on the Matching of Surface Texture Parameters and Processing Parameters of Coated Cemented Carbide Tools

Yang

Tong

2023

Coatings

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Placing micro-textures on a tool surface can play an anti-wear and friction-reducing role and capture impurities and improve the tool-chip friction state, thus improving the cutting performance of the tool and the quality of the workpiece. To ensure the processing quality in the micro-texture-coated tool-cutting process, the process parameters and micro-texture parameters are limited to smaller parameters, which reduces the processing efficiency and increases the cost. Aiming at this problem, this paper designs orthogonal experiments of the cutting process and micro-texture parameters, builds an experimental platform for milling titanium alloy with a micro-texture-coated ball-end milling cutter, analyzes the influence of cutting parameters on tool milling performance and workpiece quality, establishes a high fitting prediction model, and optimizes parameters. The results show that the cutting parameters significantly affect the milling force, tool wear, and workpiece surface roughness, which are in the first response level, and the micro-texture parameters, which are in the second response level. It is proven that micro-texture has anti-wear and anti-friction effects, and it is found that micro-texture parameters affect the evaluation index by changing the distribution state of the micro-texture. It is found that the multiple linear regression model fits better. Parameter optimization results are: v = 159.4232 (m/min), ap = 0.211 (mm), f = 0.06 (mm/r), micro-pit diameter D = 62.3429 (μm), distance from blade L = 121.5184 (μm), and micro-pit spacing L1 = 235.6443 (μm). It provides some guidance for the selection of micro-texture parameters and cutting parameters on a micro-texture-coated tool.

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Optimizing the micro-texture and cutting parameters of ball-end milling cutters to achieve milling stability

Cited by 7 publications

References 9 publications

Uniform-Density Micro-Textured Ball-End Milling Cutter Model Based on Fractal and Uniform Distribution Theory

Uniform-Density Micro-Textured Ball-End Milling Cutter Model Based on Fractal and Uniform Distribution Theory

Effect and optimization of triangular textures on lubrication performance of the thrust bearing

Study on the Matching of Surface Texture Parameters and Processing Parameters of Coated Cemented Carbide Tools

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