Other Machining Processes and Modeling Techniques

Markopoulos, Angelos P.

doi:10.1007/978-1-4471-4330-7_5

Cited by 4 publications

(5 citation statements)

References 59 publications

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“…The average surface roughness (Ra) values of the holes drilled in the workpieces are of great importance because they show the dimensional accuracy of the product and the quality of the product. Within the scope of the study, the average values of Ra were taken into consideration, adhering to the general sample acceptance condition [36]. For this purpose, Ra values of the holes drilled on AA7075 aluminium workpieces were measured very precisely using the Hommel Tester T500 brand device.…”

Section: Surface Roughness Measurementsmentioning

confidence: 99%

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Performances of cryo-treated and untreated cutting tools in machining of AA7075 aerospace aluminium alloy

Adin

2023

European Mechanical Science

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The quality of drilled holes in aluminium alloys used in the aerospace industry is vital to ensure high-precision structural integrity. For this reason, optimum selection of cost-effective cutting tools and cutting parameters is of great importance. Nowadays, due to their high cost and supply difficulties, there is a great interest in improving the performance of traditional HSS cutting tools as an alternative to ceramic, carbide and coated cutting tools. HSS cutting tools are widely used in different industries due to their cost-effectiveness and suitability to improve tool performance. In this research, the performances of cryo-treated (DC&T) and untreated (UT) HSS cutting tools used in dry machining of AA7075 aluminium alloys were investigated. Thanks to DC&T processes applied to HSS cutting tool, improvements have occurred in its microstructure. The hardness value of HSS cutting tool increased by 6.89% with the effect of DC&T processes applied. When the highest and lowest Ra values obtained using DC&T and UT HSS cutting tools were compared, it was seen that DC&T HSS cutting tool performed better by 11.05% and 25.91%, respectively. It has been determined that the hole surface quality of the aluminium workpiece machined with DC&T and UT HSS drills is negatively affected by the increase in spindle speed and feed rate. The highest S/N ratios calculated according to Ra values of holes drilled on aluminium workpieces using DC&T and UT HSS cutting tools were found to be -7.12 dB (2.27 μm) and -9.62 dB (3.03 μm), respectively. In the ANOVA analysis, it was determined that the most effective parameters on Ra values were spindle speed (70.62%), tools (18.19%) and feed rate (9.98%), respectively. In the regression analysis, R2 value for Ra values was calculated as 98.30%. High R2 value result shows that the model developed is quite successful in estimating Ra values.

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Section: Surface Roughness Measurementsmentioning

confidence: 99%

“…In the manufacturing industries, one of the ways to determine the surface quality of drilled workpieces is to measure Ra values of the holes [39]. Holes with the lowest value as a result of the measured Ra values are considered high because they increase the performance and service life of the workpiece [36,39].…”

Section: Surface Roughnessmentioning

confidence: 99%

Performances of cryo-treated and untreated cutting tools in machining of AA7075 aerospace aluminium alloy

Adin

2023

European Mechanical Science

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“…where l p is the length of the plastic interface. Based on the literature data [1] and [20] and, in particular, the results of previous research [10] and [12], the plastic interface length l p = 0.37 • l nc , identical for all cases considered, was assumed for the calculations. The calculations performed according to Eq.…”

Section: Simulation Modellingmentioning

confidence: 99%

Temperature and Heat Partition Testing in the Cutting Zone for Turning AISI 321 Steel

Bartoszuk

2020

SV-JME

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This article shows selected results of experimental tests and the results of analytical and numerical modelling of the thermal characteristics of the cutting process. The tests were conducted for the case of the dry turning of austenitic steel AISI 321 with cutting tools with a flat rake face. The research aimed to determine the actual division of thermal fluxes in the zone of contact between the chip and the rake face. As a result of such work, a formula for a new heat partition coefficient and a formula for calculating the average contact temperature were developed. The results showed that the formulas developed can be a useful tool to estimate heat distribution in the cutting zone quickly.

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“…Cutting forces, morphology of chips, stresses, strains, and temperatures can all be determined using simulation earlier than actual machining using a cutting tool. Modelling and experiments also contribute to a better understanding of fundamental problems in machining theory [2]. Mechanics of milling includes the shearing between the workpiece and the edge of the cutting tool, the e ect of friction between the chip and the rake face of the tool, and ploughing action between the machined surface and the cleared surface.…”

Section: Introductionmentioning

confidence: 99%

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

Senthilkumar

Hariharan

Tamizharasan

et al. 2022

Advances in Materials Science and Engineering

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In this present work, finite element analysis (FEA)-based simulation of end-milling of AISI1045 steel using tungsten carbide tool was performed using DEFORM-3D simulation software. Usui tool wear model, Johnson-cook material model and adaptive remeshing are considered during machining simulation. The impact of machining variables rate of feed, tool speed, and depth of cut was investigated, and the best integration of variables was distinguished for lower cutting temperature, principal stress, cutting forces, effective stresses, tool wear, and effective strain. The obtained results were correlated using experimentation in a vertical machining center attached with a Kistler tool dynamometer with data acquisition setup for capturing the cutting forces, and an infrared (IR) thermometer was used to measure the cutting temperature, and a comparison was done. Results showed a good correlation. There is a relationship between experimental and numerical results, and simulation findings can be utilised for interpreting the influence of machining parameters.

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Other Machining Processes and Modeling Techniques

Cited by 4 publications

References 59 publications

Performances of cryo-treated and untreated cutting tools in machining of AA7075 aerospace aluminium alloy

Performances of cryo-treated and untreated cutting tools in machining of AA7075 aerospace aluminium alloy

Temperature and Heat Partition Testing in the Cutting Zone for Turning AISI 321 Steel

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

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