Parameter optimization of a micro-textured ball-end milling cutter with blunt round edge

Yang, Shengqiang; Ren, Wenjie; Wang, Tianjiao; Su, Shuai

doi:10.1007/s00170-019-04499-z

Cited by 10 publications

(4 citation statements)

References 13 publications

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“…The micro-texture spacing L1 varied from 130 to 170 µm, and the radius R of the blunt circular edge ranged from 40 to 60 µm. The cutting speed v ranged from 140 to 180 mm/min, the cutting depth ap ranged from 0.3 to 0.5 mm, and the feed rate f ranged from 60 µm/z to 80 µm/z [21]. An orthogonal test table was designed to account for interactive effects, as shown in Table 3.…”

Section: Interactive Test Designmentioning

confidence: 99%

Analysis of Surface Characteristics of Titanium Alloy Milling with Ball-End Milling Cutters Based on Mesoscopic Geometric Features

Tong,

Wang,

Wang

et al. 2024

Coatings

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In order to further reduce the height of burrs on the surface of the workpiece when milling titanium alloy with ball-end milling cutters and optimize the quality of the workpiece, this article takes the mesoscopic geometric feature of ball-end milling cutters as the research object and establishes the theoretical relationship between the mesoscopic geometric feature parameters and the height of titanium alloy burrs during milling. A milling test platform was built to explore the influence of micro-texture, blunt edge single factor, and their interaction with cutting parameters on the force-thermal characteristics and workpiece burr in the milling process. The influence mechanism was revealed, and the prediction model was established. The results show that the ball-end milling cutter with mesoscopic geometric features was able to suppress burrs, and the burr height was reduced by 21% compared with the non-textured milling cutter. The micro-texture reduced the contact area and improved the heat dissipation conditions, thereby reducing the force-thermal characteristics and thus inhibiting the formation of some burrs. The blunt edge can disperse the stress, diffuse the local heat in the tool–chip contact area, and reduce the burr height. In the interaction test considering cutting parameters, the interaction between R and ap was significant. The optimized parameters based on the simulated annealing algorithm were as follows: the radius of the blunt edge was 33.242 μm, the distance between the texture and the edge was 114.621 μm, the texture diameter was 59.820 μm, the texture spacing L1 was 131.410 μm, the cutting depth ap was 0.310 mm, the cutting speed V was 140.019 mm/min, and the feed f was 60 μm/z. This provides a basis for the study of strengthening the tool to suppress burr size.

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Section: Interactive Test Designmentioning

confidence: 99%

Analysis of Surface Characteristics of Titanium Alloy Milling with Ball-End Milling Cutters Based on Mesoscopic Geometric Features

Tong,

Wang,

Wang

et al. 2024

Coatings

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“…However, there are few studies on the prediction and control of residual compressive stress based on the combination of mechanical-thermal coupling and machining parameters. Existing studies have shown that the blade edge radius and the feed per tooth are closely related to the generation of milling forces and residual compressive stress in the machining process [19]. On this basis, the relationship between the blade edge radius and the feed per tooth and the milling force and heat is further explored.…”

Section: Introductionmentioning

confidence: 99%

Residual compressive stress prediction determined by blade edge radius and feed rate during milling of thin-walled parts

Jiang¹,

Yan²,

Liu³

et al. 2022

Preprint

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Residual compressive stress can effectively improve fatigue life of aerospace thin-walled parts. In this study, residual compressive stress control is taken as the target. Firstly, a surface residual stress prediction model is proposed, which considers both machining parameters and milling force-heat. The model of the relationship between milling force, thermal load and residual stress is established, which quantifies the effects of mechanical and thermal loads on the formation of residual compressive stresses. The results show that the feed rate of each tooth and the blade edge radius play an important role in the residual compressive stress of the milling surface. The prediction models of surface residual stress for thermal load, mechanical load, feed per tooth and radius are established. Secondly, the ratio α of the feed rate per tooth fz to the blade edge radius r is calculated. When αxx = 0.42 ~ 0.65 and αyy = 0.36 ~ 0.7, the surface residual compressive stress in X and Y directions of the workpiece reaches the maximum value. Thus, the ratio of the feed rate per tooth fz to the blade edge radius r is optimized to control the mechanical and thermal load quantization. It realizes active control of residual compressive stress on workpiece surface.

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“…Gao et al [11] used the Eulerian-Lagrangian (EL) FEM model in Abaqus/Explicit for Al6061-T6 to simulate end-milling operations and accurately predicted cutting forces and chip geometry for shoulder and slot milling with up and down milling configurations. Yang et al [12] investigated the effect of a blunt round edge tool radius and microtexture characteristics on milling cutting forces and observed that the radius of a blunt round edge has the greatest effect, trailed by the tool diameter, cutting edge distance, spacing, and depth. A cutting force estimation framework centred on FEM and nonrational basis splines (NURBS) for a single blade is suggested [13], in which the cutting force estimation technique is more productive than the FEM and NURBS methods because it is established by simulation data, which may not necessitate the use of cutting force information from experiments.…”

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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Parameter optimization of a micro-textured ball-end milling cutter with blunt round edge

Cited by 10 publications

References 13 publications

Analysis of Surface Characteristics of Titanium Alloy Milling with Ball-End Milling Cutters Based on Mesoscopic Geometric Features

Analysis of Surface Characteristics of Titanium Alloy Milling with Ball-End Milling Cutters Based on Mesoscopic Geometric Features

Residual compressive stress prediction determined by blade edge radius and feed rate during milling of thin-walled parts

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

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