Papers by Keyword: End Mill

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Authors: Y. He, Zheng Qiang Yao
Abstract: End mills are very widely used in machining metal. In this paper, based on analysis of three different end milling indexable inserts with 3-D chip breaker, the influence of different chip breaker on cutting force, chip deformation and machined accuracy are studied by comparative experiments. The results show that the cutting effect of end mills with indexable inserts can be improved by optimization of 3-D chip breaker and suitable for different machining condition.
Authors: Chung Chen Tsao
Abstract: End milling is considered to be one of the most commonly applied for both roughing and finishing operations to make flat surfaces, slots and pockets in precision molds and dies. Predictive models were developed for cutting force, flank wear and surface roughness in end milling aluminum alloy by regression analysis. The correlation coefficients for cutting force, flank wear and surface roughness equations were 91.6 %, 89.8 % and 79.6 %, respectively. The goal of these predictive equations is to become a good assistant to the researcher in understanding the machining process. Through the analysis of variance (ANOVA), however, it can be found that the cutter diameter, the helix angle and the feed rate are the important milling process parameters to obtain the machined quality on cutting force, flank wear and surface roughness. The investigations show that cutting force, flank wear and surface roughness can be improved in end milling aluminum alloy by using the lower cutter diameter, medium helix angle and lower feed rate.
Authors: Kazumasa Kawasaki, Isamu Tsuji
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.
Authors: Mohd Shahir Kasim, Che Hassan Che Haron, Jaharah Abd Ghani, Juri Saedon, Mohd Amri Sulaiman
Abstract: Inconel 718 is a material exhibiting characteristic that are able to maintain strength and integrity at elevated temperatures, but it is well known as a material with poor machinability. This paper presents a study of the performance in high speed machining of TiAlN/AlCrN nanomultilayer PVD coated Inconel 718 with minimum lubrication. Investigations have been made into the effects of cutting speed, feed rate and depth of cut (DOC) on the tool life. A toolmakers microscope and a scanning electron microscope (SEM) were used to examine the tool wear and chemical attrition, respectively, on the cutting tool during machining. In the machining of aged Inconel 718, the cutting tool experienced attrition, abrasion and notch wear throughout the experiment. Notch wear was found to be the dominant failure mode during milling; this wear appeared severe when localized flank wear reached the critical zone. The influence of radial depth despite the cutting speed, well known as having the most significant effect on tool life, is also discussed.
Authors: Qing Hua Song, Xing Ai
Abstract: The strong demand for increasing productivity and workpiece quality in milling process makes the machine-tool system operate close to the limit of its dynamic stability. Milling cutters with variable pitch angles can be very effective in improving stability against chatter for certain speed ranges, which will be predicted by the model presented here. The present paper deals with the design of structural geometry of variable pitch end mills in detail. Based on the analysis of tooth engagement factor, which is expressed and extended in the paper, an approach is proposed to design variable pitch end mill with high milling stability. The certain speed ranges with high milling stability are given.
Authors: Rong Li, Xue Feng Chen, Guo Fu Ding, Jian Jun Liu, Xiao Bo Jin
Abstract: An integrated system of geometric modeling and machining simulation of end mills is presented for supporting end mill’s cutting analysis, structural optimization and digital manufacturing. In order to obtain accurate structural models, the main elements and detail features of end mills are modeled precisely, based on modular design and parametric design methodology. Through integrates 2D tool path and 3D virtual machining simulation seamlessly, a comprehensive simulation platform is constructed. To ensure the accuracy of manufacturing simulation model, the machining simulation model is compared to ideal design model. The results verify the correctness and rationality of the geometric modeling and machining simulation. NC codes generated by machining simulation can be output to tool grinder, supporting digital manufacturing of end mills.
Authors: Yoshihiko Murakami, H. Liu, H. Hanyu
Abstract: We would like to report on the development of our new ultra fine crystalline CVD diamond film and some applications. CVD Diamond films have good wear resistance, but the crystal size is too large. Therefore, in case of application of diamond films for cutting tools, we cannot get fine surface finish on work materials. Recently we succeed in production ultra fine crystalline CVD diamond film and various cutting tools as taps, drills and end mills. Aluminum alloys have lately been consumed more than ever in airplanes and automobiles for the purpose of decreasing the weight of structural materials.Copper alloys are used for the electrode of electric discharge machines (EDM) recently. EDM electrodes are required fine surface finish because the surface quality of mold depends on accuracy of EDM electrodes. Soft materials such as aluminum and copper alloys have high viscosity and additionally activity. So during cutting aluminum and copper alloys we have sometimes adhesion between cutting tools and work pieces. Diamond film on tools is able to improve the reactivity to aluminum and copper alloys. But up to now the diamond film has a lot of course crystal and tend to supply rough surface finish on work pieces. We developed ultra fine crystalline diamond film on end mills by plasma chemical vapor deposition (CVD) method. Now our aircraft, automotive and molding customers can get smooth surface finish of work pieces.Keeping ISO14001, we recommend oil free cutting with ultra fine crystalline diamond coated cutting tools. Here I introduce background of the development and cutting examples with new fine diamond coated end mills.
Authors: Hong Jun Zhang, Jian Guang Li, Tian Wei Zhang
Abstract: Using MATLAB for development tools,we has developed a set of end mills CNC grinding programming system by analysis the end mills grinding craft ,research on cutter location trajectory calculation and post-processing technology. Meanwhile, build a five-axis tool grinder grinding simulation processing by VERICUT(a kind of CNC machining simulation software), through the edge grinding simulation , we confirm the cutter location trajectory and the NC code is errorless.
Authors: Jorge Salguero, Mariano Marcos, Moisés Batista, Alvaro Gómez, Pedro F. Mayuet, Rafael Bienvenido
Abstract: A very current technique in the research field of machining by material removal is the use of simulations using the Finite Element Method (FEM). Nevertheless, and although is widely used in processes that allows approximations to orthogonal cutting, such as shaping, is scarcely used in more complexes processes, such as milling. This fact is due principally to the complex geometry of the cutting tools in these processes, and the need to realize the studi es in an oblique cutting configuration. This paper shows a methodology for the geometrical characterization of commercial end-mill cutting tools, by the extraction of the cutting tool contour, making use of optical metrology, and using this geometry to model the active cutting zone with a 3D CAD software. This model is easily exportable to different CAD formats, such as IGES or STEP, and importable from FEM software, where is possible to study the behavior in service of the same ones.
Authors: Raja Izamshah, M.Yaakob Yuhazri, Mohd Hadzley, Mohd Amran Ali, Sivarao Subramonian
Abstract: Accuracy of machined component is one of the challenging tasks for manufacturer. In the aerospace industry, machining process is widely used for fabrication of unitized-monolithic component that contains a thin-walled structure. During machining, the cutting forces cause deflection to the thin-wall section, leading to dimensional form errors that cause the finished part to be out of specification or failure. Most of the existing research for machining thin-wall component only concentrated on the process planning and the effects of cutter geometric feature is often neglected. Tool geometric feature has a direct influence on the cutting performance and should not be neglected in the machining consideration. This paper reports on the effect of helix angle on the magnitude of wall deflection. The established effects will be used for the development of high performance cutting tool for specifically machining thin-wall component.
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