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SURFACE TEXTURE ANALYSIS AFTER BALL END MILLING WITH VARIOUS SURFACE INCLINATION OF HARDENED STEEL

Michał Wieczorowski Szymon Wojciechowski Paweł Twardowski
Metrology and Measurement Systems | 2014 | No 1 | 145-156 | DOI: 10.2478/mms-2014-0014
Keywords surface texture ball end milling hardened steel
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Abstract

In this paper, an analysis of various factors affecting machined surface texture is presented. The investigation was focused on ball end mill inclination against the work piece (defined by surface inclination angle a. Surface roughness was investigated in a 3D array, and measurements were conducted parallel to the feed motion direction. The analysis of machined surface irregularities as a function of frequency (wavelength A), on the basis of the Power Density Spectrum - PDS was also carried out. This kind of analysis is aimed at valuation of primary factors influencing surface roughness generation as well as its randomness. Subsequently, a surface roughness model including cutter displacements was developed. It was found that plain cutting with ball end mill (surface inclination angle a= 0°) is unfavorable from the point of view of surface roughness, because in cutter’s axis the cutting speed vc ~ 0 m/min. This means that a cutting process does not occur, whereas on the machined surface some characteristics marks can be found. These marks do not appear in case of a* 0°, because the cutting speed vc * 0 on the fill I length of the active cutting edge and as a result, the machined surface texture is more homogenous. Surface roughness parameters determined on the basis of the model including cutter displacements are closer to experimental data for cases with inclination angles a* 0°, in comparison with those determined for plain cutting (a= 0°). It is probably caused by higher contribution in surface irregularities generation of plastic and elastic deformations cumulated near the cutter’s free end than kinematic and geometric parameters, as well as cutter displacements.

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Authors and Affiliations

Michał Wieczorowski
Szymon Wojciechowski
Paweł Twardowski

Optimization of process parameters during end milling and prediction of work piece temperature rise

N.L. Bhirud R.R. Gawande
Archive of Mechanical Engineering | 2017 | vol. 64 | No 3 | 327-346 | DOI: 10.1515/meceng-2017-0020
Keywords dry end milling Al 6063 Taguchi method ANOVA regression analysis
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Abstract

During the machining processes, heat gets generated as a result of plastic deformation of metal and friction along the tool–chip and tool–work piece interface. In materials having high thermal conductivity, like aluminium alloys, large amount of this heat is absorbed by the work piece. This results in the rise in the temperature of the work piece, which may lead to dimensional inaccuracies, surface damage and deformation. So, it is needed to control rise in the temperature of the work piece. This paper focuses on the measurement, analysis and prediction of work piece temperature rise during the dry end milling operation of Al 6063. The control factors used for experimentation were number of flutes, spindle speed, depth of cut and feed rate. The Taguchi method was employed for the planning of experimentation and L18 orthogonal array was selected. The temperature rise of the work piece was measured with the help of K-type thermocouple embedded in the work piece. Signal to noise (S/N) ratio analysis was carried out using the lower-the-better quality characteristics. Depth of cut was identified as the most significant factor affecting the work piece temperature rise, followed by spindle speed. Analysis of variance (ANOVA) was employed to find out the significant parameters affecting the work piece temperature rise. ANOVA results were found to be in line with the S/N ratio analysis. Regression analysis was used for developing empirical equation of temperature rise. The temperature rise of the work piece was calculated using the regression equation and was found to be in good agreement with the measured values. Finally, confirmation tests were carried out to verify the results obtained. From the confirmation test it was found that the Taguchi method is an effective method to determine optimised parameters for minimization of work piece temperature.

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Authors and Affiliations

N.L. Bhirud
1
R.R. Gawande
2
  1. Research Scholar, Bapurao Deshmukh College of Engineering, RSTMU, Nagpur and Mechanical Engineering Dept, Sandip Institute of Engineering & Management, Savitribai Phule Pune University, India.
  2. Mechanical Engineering Dept, Bapurao Deshmukh College of Engineering, RSTMU, Nagpur, India

Experimental and Numerical Investigation of Cutting Forces and Temperatures in Milling of Custom 450 Steel

Harun Gökçe
Archives of Metallurgy and Materials | 2022 | vol. 67 | No 3 | 843-853 | DOI: 10.24425/amm.2022.139674
Keywords End milling Finite element method Custom 450 cutting forces Cutting temperature
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Abstract

Stainless steels have a wide usage field, their needs as structural parts are increasing day by day due to their resistance to corrosion and providing sufficient mechanical strength in environments that would cause corrosion. In addition to high mechanical properties of the stainless steels, the low heat transmission coefficients bring problems during machining. In this study, the suitable cutting tool and cutting parameters have been evaluated in terms of cutting forces and the tool temperature, the experimental results and finite element analysis have been compared in the milling of Custom 450 stainless steel which offers especially an excellent working opportunity at high temperature and salinity environment. Milling experiments have been carried out using L16 experimental design for Taguchi method. Four simulations have been made using finite element method with corresponding values in L16 orthogonal array for optimum cutting tool and the results were compared in terms of cutting forces and tool temperature changes.
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Authors and Affiliations

Harun Gökçe
1
ORCID: ORCID
  1. Industrial Design Engineering Department in Gazi University, Ankara, Turkey

Verification of the Random Nature of the Experimental Data in the End-Milling Process of Aluminum Alloys

A.B. Pop Mihail Aurel Țîțu
Archives of Metallurgy and Materials | 2023 | vol. 68 | No 3 | 967-971 | DOI: 10.24425/amm.2023.145461
Keywords Al7136 end-milling process surface roughness Young’s test experiment
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Abstract

From a theoretical point of view, the research carried out in this manuscript was carried out starting from the study of the links between surface roughness and cutting speed, cutting depth and feed per tooth in the end milling process. From an experimental point of view, it started from the organization and development of the physical cutting process, the cutting regimes to be analyzed were established, after which the surface roughness was determined and measured. In this way, the connections between the factors and parameters pursued in the research resulted. The main purpose of this research is to check the random nature of the measured data related to the quality of the end milled surface of the Al7136 aluminum alloy. The main types of statistical processing performed on the sample values from the experimental measurements, the algorithms and the corresponding work modes are according to the method of research that is based on the use of the Young test. The conclusions highlighted the importance of adopting this research method and opened new directions of study.
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Authors and Affiliations

A.B. Pop
1
ORCID: ORCID
Mihail Aurel Țîțu
ORCID: ORCID
  1. Technical University of Cluj-Napoca, Northern University Centre of Baia Mare, Faculty of Engineering – Department of Engineering and Technology Management, 62A, Victor Babes Street, 430083, Baia Mare, Maramures, Romania

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