Effect of Cutting Parameters on Cutting Forces for Different Profile of Cutting

Abstract:

In machining operation of mould cavities, the tool travels in various straight and corner profiles following predetermined toolpath. Such condition results in a fluctuation of cutting forces that may produce bad surface finish. The objective of this study is to investigate the most influential parameters on cutting operation for both straight and corner profiles of pocketing operation. Cutting speeds of 150, 200 and 250m/min, feedrates from 0.05, 0.1, 0.15 mm/tooth and depths of cut of 0.1, 0.15 and 0.2 mm were selected for the cutting processes. Taguchi L9 orthogonal array with Pareto ANOVA analysis was employed to analyze the effects of the selected parameters. The result demonstrates there are different effects of cutting parameters on cutting forces for straight and corner profiles. Furthermore, it was found that cutting speed and feedrate are prevailing factors that affected cutting forces for both types of profile.

• Periodical: Applied Mechanics and Materials (Volumes 799-800)
• Pages: 361-365
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.799-800.361
• Online since: October 2015
• Authors: Roshaliza Hamidon, Erry Y.T. Adesta*, Muhammad Riza, Mohammad Iqbal
• Keywords: Corner End Milling, Cutting Force, Straight End Milling, Taguchi Method

References

[1] Z. Wei, M. Wang, and X. Han, Cutting forces prediction in generalized pocket machining, Int. J. Adv. Manuf. Technol., vol. 50, no. 5–8, p.449–458, Feb. (2010).

DOI: 10.1007/s00170-010-2528-3

[2] X. Yan, H. Tao, D. H. Zhang, and B. H. Wu, Cutting Force Prediction for Generalized Cornering Milling Process, vol. 188, p.404–409, (2011).

DOI: 10.4028/www.scientific.net/amr.188.404

[3] S. Ibaraki, D. Ikeda, I. Yamaji, A. Matsubara, and Y. Kakino, CONSTANT ENGAGEMENT TOOL PATH GENERATION FOR TWO-DIMENSIONAL END MILLING, p.6–9, (2004).

[4] A. Vijayaraghavan, A. M. Hoover, J. Hartnett, and D. a. Dornfeld, Improving endmilling surface finish by workpiece rotation and adaptive toolpath spacing, Int. J. Mach. Tools Manuf., vol. 49, no. 1, p.89–98, Jan. (2009).

DOI: 10.1016/j.ijmachtools.2008.07.015

[5] T. Ding, S. Zhang, Y. Wang, and X. Zhu, Empirical models and optimal cutting parameters for cutting forces and surface roughness in hard milling of AISI H13 steel, Int. J. Adv. Manuf. Technol., vol. 51, no. 1–4, p.45–55, Mar. (2010).

DOI: 10.1007/s00170-010-2598-2

[6] L. Tang, Z. Cheng, J. Huang, C. Gao, and W. Chang, Empirical models for cutting forces in finish dry hard turning of hardened tool steel at different hardness levels, Int. J. Adv. Manuf. Technol., Sep. (2014).

DOI: 10.1007/s00170-014-6291-8

[7] C. Gologlu and N. Sakarya, The effects of cutter path strategies on surface roughness of pocket milling of 1. 2738 steel based on Taguchi method, J. Mater. Process. Technol., vol. 206, no. 1–3, p.7–15, Sep. (2008).

DOI: 10.1016/j.jmatprotec.2007.11.300

[8] A. M. Pinar, Optimization of Process Parameters with Minimum Surface Roughness in the Pocket Machining of AA5083 Aluminum Alloy via Taguchi Method, Arab. J. Sci. Eng., vol. 38, no. 3, p.705–714, Oct. (2012).

DOI: 10.1007/s13369-012-0372-5

[9] M. H. Shojaeefard, A. Khalkhali, M. Akbari, and M. Tahani, Application of Taguchi optimization technique in determining aluminum to brass friction stir welding parameters, Mater. Des., vol. 52, p.587–592, Dec. (2013).

DOI: 10.1016/j.matdes.2013.06.003

[10] a. Banerjee, H. -Y. Feng, and E. V. Bordatchev, Process planning for corner machining based on a looping tool path strategy, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., vol. 225, no. 9, p.1578–1590, Jul. (2011).

DOI: 10.1177/0954405411401687