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Journal articles on the topic 'Face milling'

Author: Grafiati

Published: 4 June 2021

Last updated: 29 May 2022

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1

Naulakha, Niranjan Kumar, Dipesh Thapa, and Sai Kiran Reddy B. N. Karthik. "An Overview on Latest Trend of Face Milling Operation." International Journal of Trend in Scientific Research and Development Volume-2, Issue-4 (June 30, 2018): 1799–802. http://dx.doi.org/10.31142/ijtsrd14446.

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2

Kundrák, János, Viktor Molnár, István Deszpoth, and Tamás Makkai. "Productivity Considerations in Face Milling." Materials Science Forum 952 (April 2019): 66–73. http://dx.doi.org/10.4028/www.scientific.net/msf.952.66.

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The kinematic versions and applied tools of milling allow for the machining of several surfaces and surface combinations, making it a versatile and widely applied procedure. Face milling for cutting is used for the high productivity manufacturing of prismatic components. Naturally, the enhancement of productivity is a primary goal for manufacturing companies; this study analyzes the efficiency of material removal, which directly influences the time parameters characterizing production performed by face milling. The focus of the paper is to identify the selection of technological data (feed, feed rate, cutting speed, diameter of milling head) that can reduce the machining time or increase the values of material removal rate. Cutting experiments were carried out for machining prismatic components from AlSi9Cu3(Fe) aluminum alloy by diamond tools. It was found that within the performance limits of the manufacturing system it is possible to save a significant amount of manufacturing time while retaining the specified geometric accuracy and surface quality of the component.

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3

Pimenov, Danil, Amauri Hassui, Szymon Wojciechowski, Mozammel Mia, Aristides Magri, Daniel Suyama, Andres Bustillo, Grzegorz Krolczyk, and Munish Gupta. "Effect of the Relative Position of the Face Milling Tool towards the Workpiece on Machined Surface Roughness and Milling Dynamics." Applied Sciences 9, no. 5 (February 27, 2019): 842. http://dx.doi.org/10.3390/app9050842.

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In face milling one of the most important parameters of the process quality is the roughness of the machined surface. In many articles, the influence of cutting regimes on the roughness and cutting forces of face milling is considered. However, during flat face milling with the milling width B lower than the cutter’s diameter D, the influence of such an important parameter as the relative position of the face mill towards the workpiece and the milling kinematics (Up or Down milling) on the cutting force components and the roughness of the machined surface has not been sufficiently studied. At the same time, the values of the cutting force components can vary significantly depending on the relative position of the face mill towards the workpiece, and thus have a different effect on the power expended on the milling process. Having studied this influence, it is possible to formulate useful recommendations for a technologist who creates a technological process using face milling operations. It is possible to choose such a relative position of the face mill and workpiece that will provide the smallest value of the surface roughness obtained by face milling. This paper shows the influence of the relative position of the face mill towards the workpiece and milling kinematics on the components of the cutting forces, the acceleration of the machine spindle in the process of face milling (considering the rotation of the mill for a full revolution), and on the surface roughness obtained by face milling. Practical recommendations on the assignment of the relative position of the face mill towards the workpiece and the milling kinematics are given.

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4

Tang, Dong Hong, and Fang Lu. "A Cutting Force Model for Face Milling Operation." Advanced Materials Research 765-767 (September 2013): 378–81. http://dx.doi.org/10.4028/www.scientific.net/amr.765-767.378.

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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.

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5

Felhő, Csaba, Bernhard Karpuschewski, and János Kundrák. "Surface Roughness Modelling in Face Milling." Procedia CIRP 31 (2015): 136–41. http://dx.doi.org/10.1016/j.procir.2015.03.075.

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6

Brîndaşu, Paul Dan, Gabriel Vasile Oniţă, and Livia Dana Beju. "Designing an Innovative Face-Milling Cutter." Applied Mechanics and Materials 371 (August 2013): 514–18. http://dx.doi.org/10.4028/www.scientific.net/amm.371.514.

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The paper consists in a research in the design of an innovative face-milling cutter, in terms of product lifecycle management (PLM), with the help from creative design methods, such as TRIZ. The model of the lifecycle management of the cutting tools was presented, emphasizing the functional analysis and creative design phase. Based on this analysis, a new constructive variant of the milling cutter was designed and simulated with finite element method, highlighting its advantages compared with classic construction variants.

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7

Saï, K., and W. Bouzid. "Roughness modeling in up-face milling." International Journal of Advanced Manufacturing Technology 26, no. 4 (March 30, 2005): 324–29. http://dx.doi.org/10.1007/s00170-004-2305-2.

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8

Young, Hong-Tsu, P. Mathew, and P. L. B. Oxley. "Predicting cutting forces in face milling." International Journal of Machine Tools and Manufacture 34, no. 6 (August 1994): 771–83. http://dx.doi.org/10.1016/0890-6955(94)90058-2.

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9

Sletkov, V. A., V. N. Kovalev, A. F. Samardak, and V. V. Dotsenko. "Improving the effectiveness of face milling." Chemical and Petroleum Engineering 21, no. 10 (October 1985): 499–501. http://dx.doi.org/10.1007/bf01149916.

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10

Liu, Lu Ning, Zhen Yu Shi, Zhan Qiang Liu, and Hao Song. "Modal Analysis of High-Speed Face Milling System Based on Composite Structure System Analysis Method." Materials Science Forum 800-801 (July 2014): 408–13. http://dx.doi.org/10.4028/www.scientific.net/msf.800-801.408.

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This paper adopts composite structure system analysis method to perform modal analysis of high-speed face milling cutter which is mounted on the machine tool through FEM modal analysis. The key problem of this method is to obtain joint surface parameters between the machine tool spindle and face milling cutter through experimental modal analysis and MATLAB software. The joint surface parameters consist of linear stiffness, linear damping, rotation stiffness and rotation damping. After getting the frequency response function (FRF) at the tool tip of the face milling system through experimental modal analysis, the contact surface parameters can be used to eliminate the influence of the machine tool to get modal parameters of the face-milling cutter itself. Based on the finite element model of face milling cutter, composite structure system analysis method can be used easily to acquire the dynamic performance of the face milling system through FEM modal analysis, greatly to improve the reliability of modal analysis, and is helpful to the dynamic design and the structure improvement of high speed face milling cutter.

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11

Zheng, Min Li, Bin Jiang, Bin Hu Chen, and Yong Jun Sun. "Research on High Speed Face Milling Cutter Based on the Model of Stress Field." Materials Science Forum 532-533 (December 2006): 341–44. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.341.

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According to the characteristics of high speed face milling process, the models of the stress field for high speed face milling cutter with two sorts of structure are proposed and established. By means of the finite element analysis of the stress field for high speed face milling cutters, the law of influence of the cutter’s structure, the cutter’s subassemblies and the fixing rake of inserts on the stress field of cutter is acquired under the action of high rotate speed. In this foundation, the model reconstruction and the stress field analysis of the cutter are completed, and the model of evaluation for dynamic cutting performance of high speed face milling cutter is established. The results of high speed face milling experiment and frequency spectrum analysis of dynamic cutting force of the cutter indicate that high speed face milling cutter with the fixing rake of zero degree and less subassemblies takes on better dynamic high speed cutting performance.

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12

Oniţă, Gabriel Vasile. "Experimental Study of Vibrations in Face Milling Cutting." ACTA Universitatis Cibiniensis 65, no. 1 (December 1, 2014): 73–77. http://dx.doi.org/10.1515/aucts-2015-0013.

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Abstract The present paper consists in a comparison of vibrations measured during face milling cutting with two constructive variants of milling cutters (one with classic insert clamping and other with a quick insert adjustment mechanism). The goal of the study is to determine if the new clamping mechanism of the inserts has a similar behaviour with the classic one and can withstand milling conditions without introducing additional vibrations in the system

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13

An, Qing Long, Jun Li Li, Wei Wei Ming, and Ming Chen. "Finite Element Simulation on Face Milling of Austenitic Stainless Steel with Chamfered Tools." Key Engineering Materials 392-394 (October 2008): 1042–46. http://dx.doi.org/10.4028/www.scientific.net/kem.392-394.1042.

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Due to the high strength of austenitic stainless steels, it is essential for cutting tool to keep with appropriate chamfered edges during the face milling process. In this paper, face milling mechanics with chamfered edge based on cutting force and chip formation were analyzed through finite element analysis (FEA). Three kinds of tools with different chamfered edges were studied on face milling of 1Cr18Ni9Ti austenitic stainless steel. The primary research results indicated that FEA results showed good consistency with experimental results. This can provide references for development and application of tools during face milling process.

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14

Płodzień, Marcin, Łukasz Żyłka, Paweł Sułkowicz, Krzysztof Żak, and Szymon Wojciechowski. "High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude." Materials 14, no. 9 (April 25, 2021): 2196. http://dx.doi.org/10.3390/ma14092196.

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High feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the high feed milling (HFM), experimental tests were conducted, preceded by an analysis of cutting zones when milling with an HF face cutter. The face milling tests of 42CrMo4 steel with the use of an HF cutter characterized by an entering angle, dependent on axial depth of cut ap and insert radius r values, as well as with a conventional face cutter with the entering angle of 45° were performed. The study focused on analyzing the vibration amplitude, cutting force components in the workpiece coordinate system, and surface roughness. The experimental tests proved, that when milling with constant cut layer thickness, the high feed cutter allowed to obtain twice the cutting volume in comparison with the conventional face cutter. However, higher machining efficiency resulted in an increase in cutting force components. Furthermore, the results indicate significantly higher surface roughness and higher vibration amplitudes when milling with the HF cutter.

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15

Chen, Feng Jun, Shao Hui Yin, and S. J. Hu. "Modeling and Computer Simulation of Grinding for Ball-End Milling Cutter with Equal Normal Rake Angle." Advanced Materials Research 53-54 (July 2008): 225–30. http://dx.doi.org/10.4028/www.scientific.net/amr.53-54.225.

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In this paper, a new mathematical model and grinding method of ball-end milling cutter are proposed, based on the orthogonal spiral cutting edge curve. The movements of grinding wheel and ball-end milling cutter are presented while grinding rake face. In order to grind conveniently and avoid interference, a conical wheel is also designed and employed to grind the rake face of ball-end milling cutter on a grinder. In order to improve the machining characteristics of ball-end milling cutter, the model of rake face with equal rake angle is established. The software of ball-end milling cutter is developed to design and optimize different shapes of rake face. Furthermore, the simulation analysis on rake face with equal rake angle is carried out to confirm the validation of the mathematical models.

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16

Shen, Hui Cun, Wan Shuan Zong, and Ji Feng Liang. "Study on Milling Gray Cast Iron Using PCBN Indexable Face Milling Tools." Advanced Materials Research 189-193 (February 2011): 1329–33. http://dx.doi.org/10.4028/www.scientific.net/amr.189-193.1329.

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Under dry cutting conditions, multi-factor orthogonal experiment test method is adopted to carry out experiment of milling gray cast iron HT200 using PCBN indexable face milling tool. Milling force empirical formula model is established by means of least-square method and regression analysis. Significance test of regression equation and regression coefficient prove that the reliability of the established model is high. Test results show among three milling forces, the biggest one is tangential force Fz, the smallest one is radial force Fy, whereas value of axial force Fx is between Fz and Fy. Through analyzing experiment results, relationship of milling parameters influence on milling force is summarized. Recommendation of milling parameter value range is put forward.template explains and demonstrates how to prepare your camera-ready paper for Trans Tech Publications. The best is to read these instructions and follow the outline of this text.

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17

Lin, Ai Qin, Min Li Zheng, and Yan Gu. "3D Simulation and Analysis for Face Precision Milling of Aerospace Aluminum Alloy." Advanced Materials Research 188 (March 2011): 657–61. http://dx.doi.org/10.4028/www.scientific.net/amr.188.657.

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The present work aims at simulating three-dimensional milling operation of aluminum allo7451.Building a nose ring radius and edge radius tool model. Using finite element analysis software , conducted a three-dimensional simulation of milling process. Milling force, milling temperature, stress distribution and chip shape of milling process have been got. A milling force experiment was carried out under the same cutting conditions as the simulation, and a good agreement between the simulation result and the experimental result was achieved, and chip shape matched the practice well. The simulation shows that the three-dimensional finite element milling cutter model and the workpiece model can be used to correctly simulate precision milling process, optimizing the cutting parameters by analyzing variation of the cutting force, the temperature and equivalent stress.

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18

Chen, Dyi Cheng, Ci Syong You, Chia An Tu, and Chieh Hsin Ni. "Study of 6061 Aluminum Alloy Milling Using Four-Blade Face Cutter." Key Engineering Materials 661 (September 2015): 62–68. http://dx.doi.org/10.4028/www.scientific.net/kem.661.62.

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In this paper, construction of finite element analysis based on DEFORMTM 3D four-blade face milling cutter aluminum 6061 cutting, explore the finite element analysis of face milling cutter rotating in a circle cutting of aluminum alloy 6061.Tool types used WC milling cutters, cutting speed, feed rate as fixed process parameters. The study analyzed four rotations of the blade face milling chip formation, effective stress, effective strain and material changes in temperature and tool wear.

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19

Liu, Lu Ning, Zhen Yu Shi, and Zhan Qiang Liu. "Finite Element Modal Analysis for Face-Milling Cutter." Key Engineering Materials 589-590 (October 2013): 19–22. http://dx.doi.org/10.4028/www.scientific.net/kem.589-590.19.

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In this paper, a face-milling tool system is dealt with the Finite Element Modal Analysis (FEMA) using advanced contact technology functionalities. Dynamic characteristics analysis is performed and the stiffness contribution is included in the modal pre-stressed analysis. Natural frequencies and mode shapes of vibration are calculated. The FEMA is followed by experiments performed for different operating conditions of the face-milling system. The dynamic characteristics obtained in this paper can be used to optimize the face-milling cutter in high speed machining.

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20

Oniţă, Gabriel Vasile, and Paul Dan Brîndaşu. "Experimental Study of Vibrations in Face Milling Cutting." Applied Mechanics and Materials 657 (October 2014): 68–72. http://dx.doi.org/10.4028/www.scientific.net/amm.657.68.

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The paper consists of a research in designing and experimental analysis using a face milling cutter with round inserts. A general model for the new cutter is proposed taking into consideration multiple aspects regarding monitoring and controling the milling process. A comparison of measured vibrations when cutting with different parameters for two constructions of the milling head is presented. The objective of this vibration comparison is to verify wether the new design behaves in similar way with the classic and proven concept of insert clamping using a central screw.

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21

Karpuschewski, Bernhard, János Kundrák, Thomas Emmer, and Dmytro Borysenko. "A New Strategy in Face Milling - Inverse Cutting Technology." Solid State Phenomena 261 (August 2017): 331–38. http://dx.doi.org/10.4028/www.scientific.net/ssp.261.331.

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The article describes a new technology in milling of the flat surfaces - Inverse Cutting Technology. The theoretical basics of the inverse cutting are formulated. The boundary conditions of the process depending on the cutting parameters are presented. The chip formation and chip flow by inverse milling are simulated. The comparison of cutting forces by conventional and inverse face milling is shown. Finally, cutting experiments were conducted to confirm the results of the 3D-FEM-simulation.

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22

Sampath, Karthikeyan, Shiv G. Kapoor, and Richard E. DeVor. "Modeling and Prediction of Cutting Noise in the Face-Milling Process." Journal of Manufacturing Science and Engineering 129, no. 3 (January 24, 2007): 527–30. http://dx.doi.org/10.1115/1.2716702.

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A cutting noise prediction model is developed to relate the cutter-workpiece vibrations to the sound pressure field around the cutter in the high-speed face-milling process. The cutter-workpiece vibration data are obtained from a dynamic mechanistic face-milling force simulation model. The total noise predicted, based on both cutting noise and aerodynamic noise prediction, compares well to the noise observed experimentally in the face-milling process. Using the model, the effects of various machining and cutter geometry parameters are studied. It is shown that cutter geometry, machine dynamics, and cutting speed all play important roles in determining overall noise in face milling.

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23

Tapoglou, Nikolaos, and Aristomenis Antoniadis. "3-Dimensional kinematics simulation of face milling." Measurement 45, no. 6 (July 2012): 1396–405. http://dx.doi.org/10.1016/j.measurement.2012.03.026.

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24

Köhler, J., and A. Seibel. "FTS-based Face Milling of Micro Structures." Procedia CIRP 28 (2015): 58–63. http://dx.doi.org/10.1016/j.procir.2015.04.011.

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25

Sedlak, Josef, Petr Osicka, Josef Chladil, Ales Jaros, and Ales Polzer. "RESIDUAL STRESS WHEN FACE MILLING ALUMINIUM ALLOYS." MM Science Journal 2018, no. 04 (November 14, 2018): 2530–035. http://dx.doi.org/10.17973/mmsj.2018_11_201821.

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26

Gim, Jong-Seong, Dong Woo Cho, and Jang Moo Lee. "Optimal Design of Face Milling Cutter Geometry." CIRP Annals 39, no. 1 (1990): 391–94. http://dx.doi.org/10.1016/s0007-8506(07)61080-4.

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27

Lezanski, P., and M. C. Shaw. "Tool Face Temperatures in High Speed Milling." Journal of Engineering for Industry 112, no. 2 (May 1, 1990): 132–35. http://dx.doi.org/10.1115/1.2899555.

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While it is now generally understood that in continuous chip forming processes such as turning, there is no magic high speed above which tool temperature decreases and tool life increases with increased cutting speed. However, it has been suggested that this may not be the case in intermittent cutting operations such as face milling. It is argued that in such an operation, the tool temperature oscillates between an ambient value at the beginning of a cut and a maximum value at the end of a cut. As cutting speed is increased, the cutting time per cut will decrease and hence the fractional approach to the equilibrium value. Thus, even though the equilibrium temperature will increase with cutting speed, it is conceivable that the maximum temperature at the end of a cut will decrease. This possibility has been tested experimentally using the chip-tool thermocouple technique to record temperature vs time curves for a variety of cutting conditions. In no case was the exit temperature found to decrease with increase in cutting speed.

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28

Markopoulos, A. P., N. E. Karkalos, and J. Kundrák. "Nanometric face milling simulations using MD method." IOP Conference Series: Materials Science and Engineering 448 (November 30, 2018): 012006. http://dx.doi.org/10.1088/1757-899x/448/1/012006.

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29

Le Lan, J. V., A. Larue, P. Lorong, and G. Coffignal. "Form Error Prediction of Gearcases’ Face Milling." International Journal of Material Forming 1, S1 (April 2008): 543–46. http://dx.doi.org/10.1007/s12289-008-0256-0.

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30

HANASAKI, Shinsaku, Toshiaki HOSOI, Nobutoshi NAGAHATA, and Yoshio HASEGAWA. "A milling cutter with spherical rake face." Transactions of the Japan Society of Mechanical Engineers Series C 55, no. 515 (1989): 1784–89. http://dx.doi.org/10.1299/kikaic.55.1784.

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31

Park, Kyung-Hee, Gi-Dong Yang, Myung-Gyu Lee, Hoon Jeong, Seok-Woo Lee, and Dong Yoon Lee. "Eco-friendly face milling of titanium alloy." International Journal of Precision Engineering and Manufacturing 15, no. 6 (June 2014): 1159–64. http://dx.doi.org/10.1007/s12541-014-0451-5.

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32

Wang, H., H. Chang, R. A. Wysk, and A. Chandawarkar. "On the Efficiency of NC Tool Path Planning for Face Milling Operations." Journal of Engineering for Industry 109, no. 4 (November 1, 1987): 370–76. http://dx.doi.org/10.1115/1.3187141.

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Face milling operations are important for producing flat machined surfaces. Existing methodologies to generate NC tool path for face milling are employed everyday by manufacturing industries without considering the impact of tool path selection. A systematic study has been conducted in order to identify those critical control parameters affecting length of cut in face milling operations. Basic polygons, from triangles to heptagons, were planned using both window frame and stair case milling procedures. For each polygon, each vertex was introduced as a possible starting point for a single run in the window frame milling. The cutting orientation was further examined for stair case milling by enumerating the tool sweep angle from 0 to 180 (and 180 to 0 as well) degrees from each vertex. The results are analyzed and important conclusions are drawn noting the efficiency of the cutting process.

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33

Гусев, Владимир, and Vladimir Gusev. "Technology and tools for simultaneous preliminary and finish milling of intermittent weld surfaces." Science intensive technologies in mechanical engineering 2018, no. 12 (December 8, 2018): 3–8. http://dx.doi.org/10.30987/article_5bf8151e912aa3.24761645.

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The paper reports the analysis of technology and design of milling cutters for face milling and their drawbacks are defined. There is developed a combined cutter which allows carrying out weld surface preliminary and finish face milling in the course of one pass, reducing roughness and increasing machining productivity.

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34

Jiang, Bin, Min Li Zheng, Fang Xu, and Ya Guang Li. "Safety Prediction of High Speed Face Milling Cutter with Indexable Inserts." Key Engineering Materials 375-376 (March 2008): 593–97. http://dx.doi.org/10.4028/www.scientific.net/kem.375-376.593.

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Based on loads analysis and failure analysis for high speed face milling cutter with indexable inserts, the failure criterion of cutter was propounded, and the finite element model of cutter was established. By means of modal analysis and stress field analysis, the law of influence of the structure and elements of cutter on the safety of cutter was acquired, high speed face milling cutter for machining aluminum alloy was developed. According to ISO15641 international standard, safety prediction of cutter and experiments were completed. The results indicate that rigidity failure rotational speed is higher strength failure rotational speed of high speed face milling cutter, connection strength between cutter body and screw bolt affects directly the safety rotational speed of cutter. High speed face milling cutter for machining aluminum alloy possesses higher safety and better dynamic milling performance as cutting speed is less than 2820m/min.

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35

Zhang, Tao, Guo He Li, and L. Han. "Theoretical Surface Roughness Model in High Speed Face Milling." Advanced Materials Research 989-994 (July 2014): 3331–34. http://dx.doi.org/10.4028/www.scientific.net/amr.989-994.3331.

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High speed milling is a newly developed advanced manufacturing technology. Surface integrity is an important object of machined parts. Surface roughness is mostly used to evaluate to the surface integrity. A theoretical surface roughness model for high face milling was established. The influence of cutting parameters on the surface roughness is analyzed. The surface roughness decreases when the cutter radius increases, total number of tooth and rotation angular speed, while it increases with the feeding velocity. The high speed face milling can get a smooth surface and it can replace the grinding with higher efficiency.

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36

Liu, Lu Ning, Zhen Yu Shi, Zhan Qiang Liu, and Kai Feng Song. "Research on Surface Roughness in High Speed Face Milling Part 1: Theory of Prediction Model." Materials Science Forum 800-801 (July 2014): 613–18. http://dx.doi.org/10.4028/www.scientific.net/msf.800-801.613.

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The work-piece surface quality reflects the cutting performance of face-milling cutter. This paper presents the development of an algorithm to predict work-piece surface roughness in face milling operation. The prediction model is based on the face milling cutter fixed square inserts with flat edges. The static prediction model considers the effects of radial and axial run-out error of inserts, feed per tooth, tooth number, cutting edge length, nose radius, main lead angle, and axial depth of cut. The dynamic prediction model considers the effects of the Z-axial relative displacement between the work-piece and cutting teeth caused by forced vibration. By combining the prediction results of static and dynamic models, the surface roughness of the work-piece in face milling is predicted.

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37

Liu, Han Lian, Qing Ge Zhang, Chuan Zhen Huang, Bin Zou, and Hong Tao Zhu. "Experimental Study on Face Milling Austenitic Stainless Steel." Materials Science Forum 723 (June 2012): 35–40. http://dx.doi.org/10.4028/www.scientific.net/msf.723.35.

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Based on the characteristics of austenitic stainless steel 1Cr18Ni9Ti, aiming to decrease surface roughness and milling force orthogonal face milling experiment with four factors and four levels was designed to optimize machining parameters with consideration of material removal rate. Three relatively excellent machining parameters were taken to further figure out the influences of cutting speed on tool life, and the tool wear mechanism was also analyzed. The results indicated that both surface roughness and milling force were greatly influenced by cutting speed and feed. The best machining parameters obtained in the experiments were v: 200m/min, fz: 0.1mm/z, ap: 0.9mm, ae: 35mm. The main tool failure mode under this circumstance was tool chipping at the flank between main cutting edge and surface to be processed, besides, the wear of rake face was relatively slight.

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38

Ji, Sheng Yuan, Xian Li Liu, Dian Lin Ma, Yun Peng Ding, and J. Wu. "Parametric Design of Face Milling Cutter Based on UG Template Model." Advanced Materials Research 188 (March 2011): 336–39. http://dx.doi.org/10.4028/www.scientific.net/amr.188.336.

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UG template model-based parametric design method plays an important role in improving face milling cutter design efficiency and ensuring design accuracy. Three kinds of parameter design method are described in this paper. Parametric design of series for face milling cutters is completed with UG software and UG template model, moreover, user menu and an interactive window are customized, which improves design efficiency and accuracy of face milling cutter. Meanwhile, this study can provide reference for more model design and functional development.

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39

Sampath, Karthikeyan, Shiv G. Kapoor, and Richard E. DeVor. "Modeling and Analysis of Aerodynamic Noise in Milling Cutters." Journal of Manufacturing Science and Engineering 129, no. 1 (May 10, 2006): 5–11. http://dx.doi.org/10.1115/1.2335861.

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Aerodynamic noise generated in high speed face milling cutters is usually much higher than the noise exposure limit set by OSHA. Experiments were conducted on two different face milling cutters to understand the aerodynamic noise generation in face milling cutters. It is observed that dipole sources of noise are most important in determining the noise generation in rotating face milling cutters. The aerodynamic noise spectrum consists of discrete tones at the rotational frequency and a broad range of higher frequencies, with the broadband spectrum contributing significantly to overall noise. A mathematical model based on the Ffowcs Williams-Hawkings Equation is used to predict (un-weighted) aerodynamic noise. The noise predicted compares well with the experimental observations. The cutter gullet shape was found to be an important factor in determining broadband noise.

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Jiang, Bin, Min Li Zheng, Wen Chao Xu, and L. Jiang. "Structural Design Method of High Speed Face Milling Cutter Based on Theory of Axiomatic Design." Advanced Materials Research 69-70 (May 2009): 456–60. http://dx.doi.org/10.4028/www.scientific.net/amr.69-70.456.

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Using grey system theory in axiomatic design of high speed face milling cutter, the structural design method of cutter was investigated. The problem of parameter interaction and function coupling in axiomatic design of cutter was solved using the analysis method of grey cluster, and realized the reconstruction of design matrix and collaborative design planning. Results show that there is not design loop which exists in the development of high speed milling cutter, the effects of simplifying design process, shortening design cycle and improving collaborative design are validated in development of high speed face milling cutter. Results of experiments indicate that cutting vibration of high speed face milling cutter using structural design method is depressed, the cutters with higher safety and cutting stability, and their cutting performance have met the requirement of high speed milling.

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Saputro, Risdiyanto Edy, Indri Yaningsih, and Heru Sukanto. "Studi implementasi cad/cam pada proses milling cnc terhadap kekasaran permukaan dan tingkat kepresisian aluminium 6061." Jurnal Teknik Mesin Indonesia 11, no. 1 (March 5, 2018): 36. http://dx.doi.org/10.36289/jtmi.v11i1.49.

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Penelitian ini dilakukan untuk mengetahui pengaruh penerapan CAD /CAM terhadap proses penggilingan CNC terhadap kekasaran dan ketelitianpermukaan. Spesimen dibuat dengan menggunakan tujuh jenis prosespemotongan. Terdapat face milling, pocket milling, profile milling, slotmilling, pengeboran, thread milling dan surface contouring. Hasil penelitianmenunjukkan bahwa penerapan CAD / CAM dengan variasi prosespemotongan menghasilkan nilai kekasaran yang lebih rendah daripadatanpa penerapan CAD / CAM. Nilai kekasaran permukaan untuk masingmasingproses pemotongan adalah proses face milling (0,5028 μm; 0,5132μm), slot milling (0.664 μm; 0.6556 μm), profile milling (1.282 μm; 1.3128μm), pocket milling (1.3852 μm; 1.4856 μm ) Dan proses pengeboran(1.9944 μm; 2.1136 μm). Nilai rata-rata dimensi dari pengukuranmenunjukkan selisih antara hasil implementasi CAD / CAM dan tanpaimplementasi CAD / CAM. Persentase perbedaan panjang dan lebarmasing-masing 0,037%; 0,059% untuk profile milling; 0,039%; 0,061%untuk pocket milling; Dan 0.151%; 0,317% untuk pengeboran Penggunaanstatistik penerapan CAD / CAM tidak secara signifikan mempengaruhi nilaikekasaran permukaan namun memiliki pengaruh signifikan terhadapketepatan produk dengan tingkat presisi 95%.

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Lin, Ai Qin, Min Li Zheng, Chun Guang Fan, and Lin Yang. "Surface Morphology Simulation of High Speed Milled of Face Milling Cutters." Advanced Materials Research 305 (July 2011): 225–29. http://dx.doi.org/10.4028/www.scientific.net/amr.305.225.

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To surface milling cutters for research object, established considering the single spindle partial pendulum milling cutter tooth surfaces of high speed cutting 3d surface morphology simulation model by using graphic matrix transformation principle and vector algorithms. Comparing the simulation and forecast of surface morphology and surface roughness with the actual machining surface morphology and surface roughness by using the workpiece simulation algorithm meshing, we verify the correctness of the simulation model. The simulation analyses the influence regularity of surface morphology and surface roughness by changing cutting parameters and geometrical parameters. This can help us choosing the reasonable cutting parameters and geometrical parameters and have significance on the actual machining. The surface milling cutters are high efficiency and good quality of cutting big plane or curved surface. With the development of high speed cutting technology, in high speed milling process, product crumbs tumor and scales thorn hardly exists, so cutter geometrical parameters, cutting data and so on will be the main influence reasons of surface roughness. In order to satisfied the quality requirements, at present, we choice tools and determine the milling parameters depending on experience but it is limited. The surface roughness of the processing components is reflected intuitively by processed surface of microscopic geometric shape. So surface of microscopic geometric shape produced by theory emulation is significant to forecast the surface roughness and selecting reasonable cutting parameters. Currently, there are some simulation method researches about surface of microscopic geometric shape. Zhao Xiao ming et al [1, 2] has researched the simulation modeling of microscopic geometric shape of ball end mills during processing; Xu An ping et al [3, 4] has researched the simulation modeling methods of peripherally milling processing; Zhang Guang Peng et al [5] has researched the inversion multiple tooth surfaces of the milling cutter surface morphology simulation and develop simulation software. But all above researches are ideal simulation of surface shape. There are few researches about simulation of surface shape on condition of spindle partial pendulum. Based on object of surface milling cutters, this article researches simulation modeling methods of surface topography on condition of high speed milling and give an account of the corresponding simulation algorithm. From the article, we also get the influence law of microscopic geometric shape depending on different milling dosage, cutter geometrical parameters and eccentric quantity and get the significance conclusion to actual production.

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Meng, Xinxin, Youxi Lin, and Shaowei Mi. "The Research of Tool Wear Mechanism for High-Speed Milling ADC12 Aluminum Alloy Considering the Cutting Force Effect." Materials 14, no. 5 (February 24, 2021): 1054. http://dx.doi.org/10.3390/ma14051054.

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Tool wear is a major cause of accelerated tool failure during the milling of aluminum alloy. The periodically cutting force directly affect the cutting heat and tool wear due to the intermittent cutting characteristics of the milling process. The focus of this paper is to analyze the influence of the variation of cutting force on tool wear behavior. The change law of cutting force by cutting parameters was analyzed firstly. Secondly, the variation of the wear land width (VB) of tool flank face by the milling length was analyzed. Thirdly, the wear morphology and the energy dispersive spectrometer (EDS) results of tool rake face and flank face in different cutting parameters were observed by tungsten filament scanning electron microscope. Finally, considering the cutting force effect, the tool wear mechanism during high-speed milling of Aluminum-Alloy Die Castings 12 (ADC12, 12 means aluminum number 12) was analyzed. The cutting force in tangential direction is predominant during high-speed milling aluminum alloy, which decreases gradually with the increase of cutting speed but increases gradually with the feed rising. The adhesion-oxidation wear was main wear mechanism of tool rake face during high-speed milling. While adhesive wear was the main wear mechanism of the tool flank face during high-speed milling. It is found that the formation of adhesive wear is the process from particle adhesion to melting until the formation of adhesive layer, which related to the change of cutting force.

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Soepangkat, Bobby Oedy Pramoedyo, Rachmadi Norcahyo, Bambang Pramujati, and M. Abdul Wahid. "Multi-objective optimization in face milling process with cryogenic cooling using grey fuzzy analysis and BPNN-GA methods." Engineering Computations 36, no. 5 (June 10, 2019): 1542–65. http://dx.doi.org/10.1108/ec-06-2018-0251.

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Purpose The purpose of this study is to investigate the prediction and optimization of multiple performance characteristics in the face milling process of tool steel ASSAB XW-42. Design/methodology/approach The face milling parameters (cutting speed, feed rate and axial depth of cut) and flow rate (FR) of cryogenic cooling were optimized with consideration of multiple performance characteristics, i.e. surface roughness (SR), cutting force (Fc) and metal removal rate (MRR). FR of cryogenic cooling has two levels, whereas the three face milling parameters each have three levels. Using Taguchi method, an L18 mixed-orthogonal array was selected as the design of experiments. The rough estimation of the optimum face milling parameters was determined by using grey fuzzy analysis. The global optimum face milling parameters were searched by applying the backpropagation neural network-based genetic algorithm (BPNN-GA) method. Findings The optimum SR, cutting force (Fc) and MRR could be obtained by setting FR, cutting speed, feed rate and axial depth of cut at 0.5 l/min, 280 m/min, 90 mm/min and 0.2 mm, respectively. The experimental confirmation results showed that BPNN-based GA optimization method could accurately predict and significantly improve all of the multiple performance characteristics. Originality/value To the best of the authors’ knowledge, there were no publications available regarding multi-response optimization using the combination of grey fuzzy analysis and BPNN-based GA methods during cryogenically face milling process.

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De Souza, A. M., W. F. Sales, E. O. Ezugwu, J. Bonney, and A. R. Machado. "Burr formation in face milling of cast iron with different milling cutter systems." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 217, no. 11 (November 2003): 1589–96. http://dx.doi.org/10.1243/095440503771909962.

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Werda, Sana, Arnaud Duchosal, Guénhaël Le Quilliec, Antoine Morandeau, and René Leroy. "Effect of minimum quantity lubrication strategies on tribological study of simulated machining operation." Mechanics & Industry 20, no. 6 (2019): 624. http://dx.doi.org/10.1051/meca/2019057.

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The main aim of this paper was to reproduce the frictional behaviour that occurred in milling with a pin-on-cylinder system. Three different tribological tests were conducted reproducing friction phenomenon that happened in three machining conditions: (i) dry rubbing, representing the dry machining condition, (ii) MQL applied to front face rubbing which was similar to milling with MQL applied on the insert rake face and (iii) MQL applied to rear end rubbing which was similar to milling with MQL applied on flank face. Tribological tests were carried out with coated tungsten carbide pins rubbing on X100CrMoV5 steel cylinder. Apparent coefficient of friction, adhesion area and heat flux transmitted to the pin were analysed. It has been shown that MQL rear end rubbing provided a lower adhesion area and lower apparent coefficient of friction than with MQL front face rubbing. Furthermore, MQL rear end rubbing resulted in a greater cooling ability. These findings helped to explain why better results were obtained with MQL flank face lubrication in milling compared to MQL rake face lubrication.

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Lu, Xiaohong, Zhenyuan Jia, Hua Wang, Likun Si, Yongyun Liu, and Wenyi Wu. "Tool wear appearance and failure mechanism of coated carbide tools in micro-milling of Inconel 718 super alloy." Industrial Lubrication and Tribology 68, no. 2 (March 14, 2016): 267–77. http://dx.doi.org/10.1108/ilt-07-2015-0114.

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Purpose – The paper aims to study the wear and breakage characteristics of coated carbide cutting tools through micro-milling slot experiments on superalloy Inconel 718. Design/methodology/approach – During the micro-milling process, the wear and breakage appearance on the rake face and flank face of the cutting tools, as well as the failure mechanism, have been studied. Furthermore, the wear and breakage characteristics of the micro-cutting tools have been compared with the traditional milling on Inconel 718. Findings – The main failure forms of the micro tool when micro-milling Inconel 718 were tool tip breakage and coating shed on the rake and flank faces of the cutting tool and micro-crack blade. The main causes of tool wear were synthetic action of adhesive abrasion, diffusion wear and oxidation wear, while the causes of abrasive wear were not obvious. Practical implications – The changing trend in tool wear during the micro-milling process and the main reasons of the tool wear are studied. The findings will facilitate slowing down the tool wear and prolonging the tool life during micro-milling Inconel718. Originality/value – The results of this paper can help slow down the tool wear and realize high efficiency, high precision and economical processing of small workpiece or structure of the nickel-based superalloy.

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Wang, Guangyue, Xianli Liu, Weijie Gao, Bingxin Yan, and Tao Chen. "Study on the Design and Cutting Performance of a Revolving Cycloid Milling Cutter." Applied Sciences 9, no. 14 (July 21, 2019): 2915. http://dx.doi.org/10.3390/app9142915.

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Problems such as low machining efficiency, severe tool wear and difficulty in safeguarding surface quality always exist in the machining process of titanium alloy with ball-end milling cutters. To address these issues, the design and manufacture of a revolving cycloid milling cutter for titanium alloy processing were studied in this paper. Firstly, the mathematical model of the revolving cycloid milling cutter contour surface was established. The parametric equation of an orthogonal helix cutting edge curve of a revolving cycloid milling cutter is presented. Then, the bottom boundary curve of the rake face is introduced. The five-axis grinding trajectory equation of revolving cycloid milling cutter rake face was derived based on the edge curve equation and coordinate transformation. Next, fabricating the revolving cycloid milling cutter and detecting the grinding accuracy of tool profile and geometric angle were performed. At last, a contrast test regarding the performance of the revolving cycloid milling cutter and the ball-end milling cutter in cutting titanium alloy TC11 was carried out. According to the test results, in comparison to the ball-end milling cutter, the revolving cycloid milling cutter had a smaller ratio of the axial force to the tangential force. Moreover, its flank face wore more slowly and evenly. As a result, a good surface processing quality can be maintained even under larger wear conditions, demonstrating an outstanding cutting performance.

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Liu, Lu Ning, Zhen Yu Shi, Zhan Qiang Liu, and Yan Fang Wang. "Research on Surface Roughness in High Speed Face Milling Part 2: Experimental Validation of Prediction Model." Materials Science Forum 800-801 (July 2014): 619–24. http://dx.doi.org/10.4028/www.scientific.net/msf.800-801.619.

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The paper presents rigorous experimental validation results of the algorithm to predict work-piece surface roughness in face milling operation as developed in the Part 1. The experimental verification system consisting of various devices was established according to the given experimental conditions. Experimental parameters are set for steady face milling. Experimental data are collected through four experiments. These experimental data include the axial and radial run-out errors of each square insert with flat edge, the modal parameters of the face milling system, the Z-axial milling force and the measured surface contour of the milled work-piece. The trajectory of cutting teeth is calculated by the MATLAB software based on the static surface roughness model. Z-axial dynamic relative displacement between the tooth and the work-piece is obtained as the predicted dynamic surface roughness. By integrating the prediction results of static and dynamic models, the surface contour is predicted. Predicted and measured results are compared in the same figure and basically consistent. The work-piece surface roughness prediction model will be useful and valid in high-speed face milling.

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Retyawan, Okky Nugra, Indri Yaningsih, and Heru Sukanto. "Pengaruh jenis proses pemotongan pada mesin milling terhadap getaran dan kekasaran permukaan dengan material aluminium 6061." Jurnal Teknik Mesin Indonesia 12, no. 1 (March 6, 2018): 8. http://dx.doi.org/10.36289/jtmi.v12i1.63.

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Penelitian ini bertujuan untuk mengetahui pengaruh jenis proses pemotongan pada mesin penggilingan terhadap getaran dan kekasaran permukaan aluminium 6061. Spesimen dibuat dengan menggunakan tipe pemotongan face milling, profile milling, pocket milling, slot milling dan pengeboran.. Pengambilan data kekasaran permukaan dilakukan pada semua jenis proses pemotongan dengan menggunakan tes kekasaran permukaan dan data getaran yang diambil selama proses pemotongan pada jenis proses pemotongan menggunakan meter getaran. Hasilnya menunjukkan nilai kekasaran permukaan dan getaran pada face milling sebesar 0,5368 μm dan 1,03 m / s², profile milling 1.0984 μm dan 1,49 m / s², pocket milling 1.1004 μm dan 1 , 73 m / s², slot milling 1.4888 μm dan 2.44 m / s² dan pengeboran 1.9944 μm dan 18,62 m / s². Jenis proses pemotongan pada msein milling berpengaruh pada getaran dan kekasaran permukaan. Setiap jenis proses pemotongan memiliki gaya potong yang berbeda. Semakin besar gaya pemotongan yang terjadi pada setiap jenis proses pemotongan, semakin besar nilai getaran dan kekasaran permukaan terjadi.

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