Article
Engineering, Manufacturing
S. S. Rajput, C. Upadhyay, S. Gangopadhyay, F. Fernandes
Summary: The present study aims to improve understanding of the machining performance of TiAlN coated tools in face milling of AISI 1045 medium carbon steel. Three different cutting conditions (roughing, finishing, and aggressive) were investigated and their effects on cutting forces, chip temperature, tool wear, surface roughness, and chip characteristics were analyzed. It was found that the highest cutting forces were observed in the roughing condition, while the aggressive mode of machining resulted in the highest chip temperature and wear. Various types of wear were observed, including material adhesion, coating delamination, diffusion wear, attrition wear, and abrasion wear. The results of cutting forces, chip temperature, surface roughness, and chip characteristics were correlated with tool wear, providing valuable information for selecting appropriate cutting conditions in face milling of AISI 1045 steel with TiAlN coated inserts.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2023)
Article
Chemistry, Physical
Xinxin Meng, Youxi Lin, Shaowei Mi
Summary: This paper analyzed the influence of cutting force variation on tool wear behavior during the milling of aluminum alloy, focusing on the relationship between cutting parameters and tool wear, as well as the wear mechanism of tool flank face under different cutting parameters. The main findings suggest that the cutting force in tangential direction plays a predominant role during high-speed milling of aluminum alloy, with adhesion-oxidation wear being the primary mechanism on tool rake face and adhesive wear on tool flank face. Adhesive wear is related to the change of cutting force and occurs through a process from particle adhesion to melting to the formation of an adhesive layer.
Article
Automation & Control Systems
Xi Chen, Zhao Zhang, Qi Wang, Dinghua Zhang, Ming Luo
Summary: This paper proposes a cutting force prediction method that takes into account the influence of the machine tool system and tool wear on milling force, thereby improving the accuracy of the prediction.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Yaonan Cheng, Chunjie Ma, Jianyu Zhang, Huan Zhou, Liming Xin, Xinyu Wang
Summary: This study investigates the wear mechanism of high-speed dry gear hobbing through theoretical support, finite element simulation analysis, and experimental verification. The study discusses the variations and characteristics of cutting force, tool temperature distribution, tool wear, and wear morphology and mechanism under different cutting parameters.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Irfan Ullah, Song Zhang, Qing Zhang, Renwei Wang
Summary: This study investigates the numerical methodology for serrated chip formation during high-speed milling of Ti-6Al-4V alloy and validates the model through experimental results. The impact of friction coefficient on shear stress, as well as the microstructural changes and phase transformation during chip formation, are highlighted and discussed. The findings are beneficial for optimizing process parameters and maintaining desirable machined surface integrity.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Automation & Control Systems
Guangchao Han, Zejiu Ye, Jie Xu, Yuan Ma, Chao Xu, Xueqi Zhao, Liudong Yu, Pingfa Feng, Feng Feng
Summary: This study investigated the effects of high-speed longitudinal-torsion ultrasonic vibration milling (LTUVM) on cutting forces and tool wear in comparison to conventional milling (CM) for Ti-6Al-4V. The results showed that ultrasonic vibration significantly improved tool wear, although the improvement effect on cutting forces decreased with increasing linear velocity. This study reveals the effectiveness of ultrasonic vibration in high-speed milling of titanium alloys.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Chemistry, Analytical
Tongshun Liu, Qian Wang, Weisu Wang
Summary: In this study, a nonlinear mechanistic cutting force model considering the comprehensive effect of cutting-edge radius and tool wear on the micro-milling force is constructed for micro-milling tool wear monitoring. A stepwise offline optimization approach is proposed to estimate the multiple parameters of the model. Experiments show that, compared with the linear model, the nonlinear model has significantly improved cutting force prediction accuracy and tool wear monitoring accuracy.
Article
Automation & Control Systems
Tongshun Liu, Yayun Liu, Kedong Zhang
Summary: In this study, a comprehensive micro-milling force model is derived, considering the effects of tool runout, cutting edge radius, and tool wear on cutting force. Experimental results show that the proposed model is efficient in predicting the nonlinear cutting force in micro-milling.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Electrical & Electronic
Qinghua Li, Chunlu Ma, Lintao Xie, Baizhong Wang, Shihong Zhang
Summary: In this paper, a coated composite micro-textured tool is introduced to study its influence on chip shape and cutting force under the same cutting parameters. The combination of cutting force and cutting temperature is optimized based on cutting test. Three kinds of composite micro-texture tools are tested to determine the optimum combination from the angle of chip shape, cutting temperature and cutting force. It was found that the chip was more easily broken in the composite microstructure when two tools were used, resulting in a decrease in cutting force and cutting temperature compared with non-micro-texture tools.
Article
Engineering, Manufacturing
Guohe Li, Meng Liu, Shanshan Zhao
Summary: The study establishes a 3D thermo-mechanical coupling model to accurately predict cutting force and chip morphology by reducing the volume of the workpiece model. Experiment on high-speed milling of 6061-T6 Aluminum alloy reveals varying effects of different factors on cutting force and temperature.
MACHINING SCIENCE AND TECHNOLOGY
(2021)
Article
Automation & Control Systems
Xiaohua Zhu, Jiangmiao Shi, Yunhai Liu, Yuhong Jiang, Bowen Zhou, Xiao Zhao
Summary: This study investigates the formation mechanism of serrated chips in Ti-6Al-4V titanium alloy through a two-dimensional cutting simulation model. The research reveals the occurrence of shear slip and a dead zone of temperature and stress during the cutting process, resulting in the formation of curled and serrated chips.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Guolong Zhao, Jichao Song, Zhiwen Nian, Lianjia Xin, Liang Li, Ning He
Summary: Micro-milling is widely used in processing micro-parts and structures, but the existence of chatter reduces efficiency and surface quality. This study focuses on the influence of tool wear on chatter stability using an improved time-varying stability analysis model. Experimental results validate the accuracy of the modified force model and the stability analysis considering tool wear, providing theoretical and technical guidance for improving chatter stability and developing online monitoring in micro-milling processes.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Manufacturing
Janos Kundrak, Bernhard Karpuschewski, Zoltan Palmai, Csaba Felho, Tamas Makkai, Dmytro Borysenko
Summary: This article summarizes the results of a project to study the cutting force during milling, which includes analyzing the technology using FEM simulation and validating it through cutting force measurements. The calculations show the importance of the chip ratio in determining the specific features of the technology, and it is advisable to avoid a chip ratio of ap/fz = 1 from an energy perspective.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Liang Liang, Guozhi Lin, Huanheng Tan, Jiandong Yuan, Lin He, Changcheng Jiang, Xiaoqiang Li
Summary: Anticipation of the critical cutting condition for the transition of continuous chip to serrated chip is a fundamental task in machining of ductile metallic material. In this study, an improved predictive method utilizing the variation of dynamic yield stress with cutting speed was proposed and validated, showing superior calculation and prediction efficiency compared to traditional methods.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Engineering, Mechanical
Hewu Sun, Bin Zou, Peng Chen, Chuanzhen Huang, Guoqiang Guo, Jikai Liu, Lei Li, Zhenyu Shi
Summary: Ceramic tool materials are ideal for machining superalloy materials due to their excellent heat resistance, chemical stability, and high temperature hardness. This study found that the use of lubricant and lubricant mixed with water can reduce milling force and cutting temperature, improve surface quality of the workpiece, and limit tool wear.
TRIBOLOGY INTERNATIONAL
(2022)