Papers by Keyword: Face Milling

Abstract: Carbon Fiber Reinforced Plastic (CFRP) is a high-strength and high-elastic-modulus composite material that is hardened by impregning carbon fiber with epoxy resin. Although, many sutdies of hole drilling of CFRP have been conducted, few sutdies of face milling of CFRP have been carried out. Face milling is necessary for surfaceing of aerospace parts, which is indispensable for airplane construction. Machining of CFRP is difficult because of the extreme tool wear and delamination that occur. The authors investigated face milling of CFRP using a newly developed Poly Crystalline Diamond (PCD) tool. The resultts show, that the cutting force and surface roughness are affected by the fiber orientation of the CFRP, and that delamination can easily occur in the outer layer of face-nilled CFRP.

Abstract: Since demands for Carbon Fiber Reinforced Plastics (CFRP) are increasing, the number of the studies on machining of CFRP is also increasing. However, since there are already reports on a trimming of a surplus portion or a drilling, we focus on a face machining and a generating the step shape with several cutting tools. Problems in the machining of CFRP include an occurrence of the burr and delamination. Therefore, in this report, we investigate these problems in face milling. And, the machining behavior (Cutting temperature, Cutting force) during the machining is estimated.

Abstract: In this work, the effects of two key factors of face milling including the number of inserts and insert material on surface roughness of cast-iron turbine housing work were systematically studied using full factorial designed experiments. Three insert materials including uncoated cemented carbide (TH10), commercial TiAlN/TiN coated cemented carbide (AH120) and tungsten carbo-nitride (WCN) coated cemented carbide were selected while the number of inserts was varied from 1 to 3 in this study. The results showed that both factors were statistically significant and the optimal parameters that yielded minimum Ra-value of 0.495 μm were the commercial TiAlN/TiN coated cemented carbide material (AH120) and three inserts.

Abstract: An experimental study on milling of Invar36 was conducted by using coated carbide insert to characterize the cutting force. The Taugchi's design of experiment was used for experimentation and the cutting force regression equation was established based on the principles of probability statistics and regression analysis. The results showed that the cutting force was significantly affected by the axial depth of cut and the feed per tooth, and with the increase of the axial depth of cut, the cutting force increased very quickly. Compared with the axial depth of cut, radial depth of cut and cutting speed had less influence on the cutting force. The established regression equation was highly reliable.

Abstract: The purpose of this research was to investigate the effect of the main factors on the surface roughness in mold steels face milling by carbide tool for results obtained from the analysis used in the manufacture of molds and other parts of the industry. The etching experiment using semi-automated milling machine Obraeci Strojie brand FGV 32 model. Concerning the material was steel grade AISI P20 mold with a hardness between 280-325 HB which used to insert carbide tool. The factors of a speed, feed rate and depth of cut were study. Preliminary experiments showed that the depth does not affect the surface roughness fix depth of cut at 0.5 mm. The experimental revealed that the factor affecting surface roughness was feed rate and speed. The roughness value trenced to reduce at lower feed rate and greater speed. It was possible determine a facing condition by means of the equation Ra = 1.29 - 0.000654Speed + 0.00305Feed rate leading this equation goes to use is in limitation speed 500-1,000 rpm. at feed rate 160-315 mm/min. From the experiment was confirming the result of a comparison between the equation and the percent accuracy with the margin of error. The result from the experiment of mean absolute percentage error (MAPE) of the equation of surface roughness was 3.27% which was less than the margin of error and was acceptable. The pattern of wear was similar to mechanical fatigue cracking. It may be due to the verious tip of the cutting tool or an impact and flank wear as cutting tool materials resistant to wear less.

Abstract: Tool condition monitoring is an important issue in the advanced machining process. Existing methods of tool wear monitoring is hardly suitable for mass production of cutting parameters fluctuation. In this paper, a new method for milling tool wear condition monitoring base on tunable Q-factor wavelet transform and Shannon entropy is presented. Spindle motor current signals were recorded during the face milling process. The wavelet energy entropy of the current signals carries information about the change of energy distribution associated with different tool wear conditions. Experiment results showed that the new method could successfully extract significant signature from the spindle-motor current signals to effectively estimate tool wear condition during face milling.

Abstract: This study employed the Taguchi approach in combination with finite element analysis (DEFORM3D) to investigate face milling process onto AL6061. The factors studied in this investigation were cutting speed, feed rate, and axial rake angle. The simulation of flank wear was generated according to Usuis wear model though the L₉ (3⁴) of the orthogonal array experiment. ANOVA analysis and F test were conducted to find the significant factor that contributes to tool wear in the signal to noise ratio. Finally, the confirmation test has been carried out at optimal parameter.

Abstract: In the present study, high-speed and ultra-high-speed face milling of AISI H13 steel (4647 HRC) was conducted in order to acquire a thorough understanding of the Al₂O₃-based micro-nanocomopsite ceramic cutting tool AWT10 wear mechanisms in high-speed hard milling. For different cutting speeds, the typical tool wear mechanisms is analyzed and compared. The analysis of the tool wear show that abrasive wear, adhesive wear, spalling and breakage are the primary wear mechanisms of AWT10 when cutting speed reaches 3000m/min. Micro-nanocomposite ceramic material AWT10 has favorable property of shock resistance. Improved cutting speed is in favor of cutting force reduction.

Abstract: Based on the geometry of the cutter, the dynamic force model of face milling was established. Meanwhile, the fast and effective identification method of milling force model coefficients was provided, which combining the virtues of both orthogonal design theory and partial least-square regression (PLSR) method. Milling experiments have been conducted to verify the proposed face milling force model. Good agreements between the experimental and simulated results were presented.

Abstract: The purpose of this research was to investigate the effect of the main factors of the surface roughness in semi-solid 6061 aluminum face milling. This study was conducted by using computer numerical controlled milling machine. The controlled factors were the speed, the feed rate and the depth of cut which the depth of cut was not over 1 mm. For this experiment, we used factorial designs and the result showed that the factors effected of surface roughness was the feed rate and the speed while the depth of cut did not effect with the surface roughness. Furthermore, the surface roughness was likely to reduce when the speed was 4,200 rpm and the feed rates was 1,300 mm/min. The result of the research led to the linear equation measurement value which was R_a = 0.186 - 0.000034 Speed + 0.000047 Feed rate. The equation formula should be used with the speed in the range of 3,200-4,200 rpm, feed rate in the range of 1,300-1,800 mm/min and the depth of cut not over 1 mm. The equation was used to confirm the research results, it was found that the mean absolute percentage error of the surface roughness obtained from the predictive comparing to the value of the experiment was 4.12%, which was less than the specified error and it was acceptable.