The Effect of the Shape of Chip Cross Section on Cutting Force and Roughness when Increasing Feed in Face Milling

Abstract

In this paper, the results of an investigation done with face milling are presented. The changes in cutting force and surface roughness were studied through changing the values of depth of cut and the feed per tooth. Meanwhile the permanent value of the undeformed chip cross section, which was determined (fz and ap), remained permanent. Increasing fz and keeping the same value of Ac chip cross section, the ratio ap/fz changed in five grades from 0.5 to 8. It is shown, that if the feed is increased in the examined range so that the chip cross section is constant, then the value of the cutting force decreases, which decrease can be observed in all three force components. Accordingly, the mechanical power required for cutting is reduced. The results of the surface roughness investigations showed that initially a significant increase can be observed in the roughness with the gradual increase of the feed (up to ap/fz = 2.5), followed by a moderate increase afterwards.

Effect of the Relative Position of the Face Milling Tool towards the Workpiece on Machined Surface Roughness and Milling Dynamics

“…Contrarily, in the case where the result of the experiment is the most desirable, the partial desirability reaches 1. Thus, in the current approach, the highest partial desirability values were allocated to the lowest values of measured forces, vibrations, and surface roughness parameters in the whole conducted experiment (see Equations (6), (10), (14), (18, (22), (26), and (30)). On the other hand, when the less desirable effect has been reached (e.g., the highest values of measured forces, vibrations, and surface roughness parameters), partial desirabilities were equal to 0 (Equations (9), (13), (17), (21), (25), (29), and (33)).…”

“…Kundrák et al [26] studied the variation in cutting force and surface roughness for face milling resulting from variable magnitudes of cutting parameters. Lopes-da Silva and Hassui [27] studied the effects of tool path along with the process parameters on cutting forces and surface roughness.…”

“…Yıldırım et al [28] analyzed the effect of cutting parameters and cooling and lubrication conditions on tool wear and surface roughness when milling on the basis of Waspaloy nickel ceramic tools. However, references [9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26][27][28] were not concerned with proposing the optimal position of the face mill and the workpiece that provides the minimum surface roughness.…”

“…Grzenda and Bustillo [34] examined the possibility of using unlabeled data streams to develop prediction models. However, papers [26][27][28][29][30][31][32][33][34] did not describe the optimum position of the face mill and the workpiece that provides the minimum surface roughness either.…”

A forgácsolóerő vizsgálata nyolcszögletű lapkával végzett homlokmarásnál

“…Korábbi publikációkban bemutattuk C45 acél homlokmarásánál az előtolásnak és a forgácsoló sebességnek a forgácsolóerő összetevőire gyakorolt hatását mind a munkadarab, mind a szerszám koordináta rendszerében értelmezve [11]. Elemeztük a különféle alakú forgács keresztmetszetek és az előtolás hatását a forgácsolóerő komponensekre, valamint a megmunkált felület érdességére [12]. Megvizsgáltuk a forgácsolóerő változását különböző forgácsoló sebességeknél, állandó és változó forgács keresztmetszet esetben is [13].…”