Papers by Keyword: End Mill

Abstract: Inconel 625 alloy consisting of Ni and Cr and others has advantageous properties such as heat resistance and corrosion resistance, which make it a suitable material for application in aerospace, energy, and marine industries. However, it is also a difficult-to-machine material because of factors such as work hardening, low thermal conductivity, and high tool affinity. Therefore, the problems of the tool wear, chipping, and adhesion often occur in milling of Inconel 625 alloy using end mills. In this study, the milling of Inconel 625 was conducted using coated cemented carbide end mills, and the cutting conditions with the high efficiency were investigated under three rotational speeds and four feed rates. The results showed that increasing the feed rate increased the surface roughness, but did not increase the tool life. In addition, the results also showed that increasing the rotational speed did not increase the tool life, but reduced the surface roughness. As a result, the effects of the rotational speeds and feed rates on the tool life were clarified.

Abstract: This paper studied chip morphology in end milling of aluminium alloy 6061 by various cutting parameter such as feed rate, cutting speed and depth of cut. Slot milling operation were conducted. The analysis consists of chip morphology, chip weight, chip thickness and chip length. Scanning Electron Microscope (SEM) were used to obtain and examine the chips. Result shows that, end milling with higher cutting speed, feed rate and depth of cut generated short, small and light weigh of chips.

Abstract: A machining method of large-sized spiral bevel gears in cyclo-palloid system has been developed using a computer numerical control (CNC) machining center. As a result of trial machining, the tooth surfaces were rough and leprous tool mark occurred. Therefore, the tooth surfaces were polished using a poly-vinyl alcohol (PVA) elastic grindstone after machining in order to improve the surface roughness and the occurrence of leprous tool mark. However, the wear and clogging of the elastic grindstone occurred after polishing. In this paper, the tooth surfaces of the large-sized spiral bevel gears are polished using a radial bristle brush instead of a PVA elastic grindstone. The swarf cutting that was machined by the side of a tool was carried out in polishing in order to make the life of the radial bristle brush. After polishing, the tooth surface was observed and the surface roughness was measured. Afterwards, the surface roughness and the occurrence of leprous tool mark before and after polishing were compared. As a result, the surface roughness and the occurrence of leprous tool mark were improved.

Abstract: Chatter vibration in end milling remains a serious problem for manufacturing engineers. Chatter vibration often leaves a characteristic pattern or chatter mark on the machined surface. Chatter marks are generated by the relative displacement of the tool and the workpiece. Closer observation of chatter marks may prove useful in understanding chatter vibration. In this study, we investigated chatter mark patterns on end-milled surfaces. Based on these observations, we proposed and demonstrated the effectiveness of an iterative analysis method to identify stable machining conditions and minimize chatter vibration in various operations without use of sensors under specific conditions.

Abstract: The existing end mill is hard to balance the tool rigidity, heat dissipation and chip evacuation. In this study, the geometries of groove and micro-blade of the end mill machining titanium are optimized, through imitating the corn leaf’s tooth based on bionics. The peripheral cutting edge is composed of linear first rake, parabolic second rake and rear face. The chip-hold groove is composed of parabolic main groove and cubic curve vice groove. The cutting process of straight tooth and designed composite tooth are simulated by constructing the two-dimensional orthogonal cutting model using ABAQUS. The results show that: compared to the straight tooth, the designed composite tooth inhibits the generation of serrated chip, and the fluctuations of cutting force are smaller, the squeezing effect on the machined surface is weaker.

Abstract: An optimization method of end mill geometry parameters is presented for minimizing cutting energy. The helical end mill geometry is established at first. Then, the helical flutes are decomposed a set of infinitesimal oblique cutting edges. At every oblique cutting element, the differential cutting energy, which consists of differential shear energy and differential friction energy, is calculated using oblique cutting theory. By integrating the differential cutting energy along each cutting edge in the end mill, the cutting energy can be predicted during end milling. The effects on cutting energy of end mill geometry parameters are analyzed. Finally, the end mill geometry can be optimized in order to minimizing cutting energy.

Abstract: Cutting temperature is a key factor in impacting the solid carbide end mill’s life, the rule of solid carbide end mill temperature field is the research focus. In this paper, the solid carbide end mill helical side edge is regarded as a helical coil heat source, the tool chip friction surface is considered as a surface heat source which consists of countless helical coil heat source. Based on heat source method, the model of continuous dynamic temperature field simulation of a solid carbide end mills cutting process is established.

Abstract: The thin-walled component is mostly used in the aerospace industry. During machining the thin-walled components, deflection of wall occurs and causes the surface dimensional error. This paper focuses on the effect of end mill helix angle on the surface dimensional error and surface roughness when machining thin wall structure. End mills uncoated carbide were fabricated with a difference helix angle which are 25°, 30°, 35°, 40° and 45°. The results show, helix angle 35° produce smaller surface dimensional error and smoothest followed by 40°, 45°, 30° and 25°. The smaller helix angle provided high cutting force that causes more surface dimensional error due to chatter and reduction of contact time when then end mill engage with the workpiece material. Results from this research help to guide the machinist to machine thin-wall component with the right cutting tool.

Abstract: Large-sized spiral bevel gears are usually manufactured based on a cyclo-palloid system and have equi-depth teeth as well as a face hobbing system by a continuous cutting procedure using a special generator. It has been possible to machine the complicated shape because of the development of a multi-axis control and multi-tasking machine tool.The manufacturing method of the gears has been proposed using this development process. In this method, the spiral bevel gears are modeled based on a CAD system and are machined based on a CAM system. In this paper, the cutting performance in machining of the large-sized spiral bevel gears using the multi-axis control and multi-tasking machine toolis investigated. As a result, the relationship between the tool life of end mill and gear accuracy were made clear. The surface roughness and tool mark of the machined gears were compared with those using the special generator.

Abstract: Inconel 718 is a registered trademark of Special Metals Corporation that refers to a family of austenitic nickel-chromium-based super alloys. This material usually being used or operate in high temperature and extreme condition like aerospace industry, turbocharger rotors and seals. This research presents an experimental study of the cutting force variation, surface roughness, tool life and tool wear in end milling Inconel 718. The experimental results showed that flank wear was the predominant failure mode affecting tool life for TiAlN and TiN coated carbide tool. TiAlN is the better coated tool than TiN because it produce better surface finish and resultant force. Feed rate is one of the parameter that effecting results in this experiment. The higher feed rate will shorten the life of the tool. Although for the cutting condition, the situation is quite different where the proper cutting speed will maintain the tool life and tool wear for cutting tool. The overall study shows that TiAlN coated carbide tool with cutting speed 100 m/min, depth of cut 0.5 mm and feed rate 0.1 mm/tooth is the optimum parameter in this experiment.