The influence of tool-surface contact on tool life and surface roughness when milling free-form geometries in hardened steel

Scandiffio, Innocenzo; Diniz, Anselmo Eduardo; Souza, Adriano Fagali de

doi:10.1007/s00170-017-0093-8

Cited by 17 publications

(7 citation statements)

References 13 publications

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“…Scandiffio et al studied the influence of effective cutting speed and tool-surface contact on tool wear and surface roughness. Contrary of other studies, they found that contact between the centre of the tool tip and the workpiece can increase tool life and reduce roughness when milling free-form surfaces in hardened steel [30]. Cao et al proposed a cutting force model considering influence of radius of curvature.…”

Section: The Effects Of Milling Strategies On Forces Materials Removamentioning

confidence: 94%

The Effects of Milling Strategies on Forces, Material Removal Rate, Tool Deflection, and Surface Errors for the Rough Machining of Complex Surfaces

Bagci

Yuncuoglu

2017

SV-JME

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Sculptured/curved surfaces, today, are widely used in several industries, for instance, automotive, aerospace, bio-medical components, precision machine design and die-mould industries. Recent improvements in CAM software have allowed the manufacturing of complex curved geometries. The ball-end/nose milling is a flexible process that is capable of milling both convex and concave part surfaces with rough, semi-rough and finish processes. The sculptured surface milling is mostly realized by the repeated motion of a rotating cutter along predefined trajectories. Manufacturing engineers can choose the cutter paths generation approach from a set of typical paths (zig, zig-zag, concentric, radial tool paths, etc.) in commercial CAM software. In addition, these strategies cannot be optimized for all complex surfaces to be milled. A substantial number of studies have examined this subject, and many path-generation approaches have been developed, as shown in Fig. 1 [1] and [2].The strategies can be sorted into three basic categories: offset, single direction, and raster. In offset milling, the cutter starts at the periphery of the face and then proceeds spirally inwards. In a raster milling strategy (zig, zig-zag, or sweep) the cutting tool moves back and forth across the milled workpiece [3]. In spiral milling, the cutter returns to the start-point of each cycle and then cuts outwards to the next outer cycle. When using a spiral strategy, the cutting time is hugely decreased. The selection of the proper milling strategy in the process of milling will decrease cutting time, improve the surface quality of the finished part and tool life and reduce machining costs and cutting forces. Kurt

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Section: The Effects Of Milling Strategies On Forces Materials Removamentioning

confidence: 94%

The Effects of Milling Strategies on Forces, Material Removal Rate, Tool Deflection, and Surface Errors for the Rough Machining of Complex Surfaces

Bagci

Yuncuoglu

2017

SV-JME

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“…The results of the previous author's studies show that the surface roughness is influenced by the inclination of the tool [2,14,21]. Surface roughness can affect accuracy [28][29][30][31][32][33][34][35][36]. Selected roughness parameters compare the peaks that can affect geometric accuracy.…”

Section: Surface Roughness Measurementmentioning

confidence: 99%

Increasing the Accuracy of Free-Form Surface Multiaxis Milling

et al. 2020

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This contribution deals with the accuracy of machining during free-form surface milling using various technologies. The contribution analyzes the accuracy and surface roughness of machined experimental samples using 3-axis, 3 + 2-axis, and 5-axis milling. Experimentation is focusing on the tool axis inclination angle—it is the position of the tool axis relative to the workpiece. When comparing machining accuracy during 3-axis, 3 + 2-axis, and 5-axis milling the highest accuracy (deviation ranging from 0 to 17 μm) was achieved with 5-axis simultaneous milling (inclination angles βf = 10 to 15°, βn = 10 to 15°). This contribution is also enriched by comparing a CAD (Computer Aided Design) model with the prediction of milled surface errors in the CAM (Computer Aided Manufacturing) system. This allows us to determine the size of the deviations of the calculated surfaces before the machining process. This prediction is analyzed with real measured deviations on a shaped surface—using optical three-dimensional microscope Alicona Infinite Focus G5.

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“…This phenomenon is particularly visible for machining of the hard-to-machine materials like steel in a hardened state, during which large values of the total cutting force components are observed, resulting in large deformations of the cutting tool [26]. In order to limit the values of the cutting force and tool deflection, the tool should be as small as possible and have small outriggers [27]. The usage of the inclination of the cutting tool in the form of a spherical cutter has a positive effect on the geometric structure of the surface.…”

Section: Milling Of Free-form Surfaces On Multi-axis Machine Toolsmentioning

confidence: 99%

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

Matras

Zębala

2020

Materials

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This work deals with technological considerations required to optimize the cutting data and tool path pattern for finishing the milling of free-form surfaces made of steel in a hardened state. In terms of technological considerations, factors such as feed rate, workpiece geometry, tool inclination angles (lead and tilt angles) and surface roughness are taken into account. The proposed method is based on calculations of the cutting force components and surface roughness measurements. A case study presented in the paper is based on the AISI H13 steel, with hardness 50 HRC and milling with a cubic boron nitride (CBN) tool. The results of the research showed that by modifications of the feed value based on the currently machined cross-sectional area, it is possible to control the cutting force components and surface roughness. During the process optimization, the 9% and 15% increase in the machining process efficiency and the required surface roughness were obtained according to the tool inclination angle and feed rate optimization procedure, respectively.

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The influence of tool-surface contact on tool life and surface roughness when milling free-form geometries in hardened steel

Cited by 17 publications

References 13 publications

The Effects of Milling Strategies on Forces, Material Removal Rate, Tool Deflection, and Surface Errors for the Rough Machining of Complex Surfaces

The Effects of Milling Strategies on Forces, Material Removal Rate, Tool Deflection, and Surface Errors for the Rough Machining of Complex Surfaces

Increasing the Accuracy of Free-Form Surface Multiaxis Milling

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

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