Structural improvement of face mills designs based on systems approach (original) (raw)
Related papers
Innovative Round Insert Face-Milling Cutter - Design and Verification
2016
Machining operations represent a significant part of the entire mechanical processing that is done in industry. Current research in material processing techniques determines the necessity of new construction variants for the cutting tools, with more efficient, cheaper and intelligent exploitation. The present paper consists in an analysis of a new round insert face-milling cutter starting from the preliminary design phase, in which creative design methods are used, simulations by means of the finite element method, in order to obtain the optimum construction variant that can withstand milling conditions and finishing with physical cutting trials.
Face milling is a well known commercial process highly used in heavy industries that consumes high amount of power. Besides power issue, modern manufacturing industries are aiming for per part cost reduction keeping the product quality unimpaired. Unexpectedly if the part is rejected in any stage of manufacturing, the cost of manufacturing dramatically increases. Major cause of part rejection is excessive tool wear that imparts poor surface profile or catastrophic tool failure that causes adherence of broken tool debris onto machined surface. Furthermore, the tool wear is associated with sliding distance (frictional distance) and the tool life quantifies the cost of tools. As such, from the perspective of manufacturing industries it is imperative to optimize the surface quality parameter, cost of part, power consumption, and material removal – this is exactly what is accomplished here. By this work, it is possible to conserve power consumption, produce parts with lower cost, manufac...
Face Milling with a Round Insert at Various Cutting Speeds and Feed Rates
Cutting & Tools in Technological System, 2019
Face milling is frequently used for the rendering of flat surfaces with a high degree of precision. With this machining process, high material removal rate is possible to be attained but management of cutting forces values is also desirable, in order to avoid excessive power consumption, tool wear or vibrations. This can be achieved by selecting the process parameters within an appropriate range for each case. In the present study, an experimental investigation is conducted with a view to determine the effect of two important process parameters, namely cutting speed and feed on the cutting forces and the specific cutting forces during face milling, in cases where a round insert is used.
Scientific journal of the Ternopil national technical university, 2019
The paper deals with the problem of determining the power characteristics of face milling process by computer modelling in DEFORM 3D environment. The influence of the rake face shape of round face mill inserts on the contact area of the chips with the inserts surface, the conditions of the chip removal, the dynamic power loads both during the inserts entry into the workpiece and after the cutting are investigated. The efficient use of inserts with cylindrical rake face in the face mills designs proved, as these results in the decrease of the chip contact area with the inserts surface and improvement of the chip removal conditions. It results in the reduction of the tool dynamic force load, both at the time of entrance to the workpiece, and during cutting. Using computer modelling of the milling process for parts flat surfaces made from hardened high-strength steel and titanium alloy, strength characteristics are determined for the operation conditions with the stepped face mill with cylindrical rake face of the inserts and the standard mill with round inserts. For the stepped face mill the reduction of both impact loads during the entrance the insert to the workpiece and the average values of the component Pz of the cutting force is confirmed in comparison with the standard mills for the various processed materials. The reduction of torque from component Pz action creates the premises for reducing the effective power of the main movement of the machine drive, what can be used for machining with increased depth of cutting on low power machines. This may be another way of increasing the efficiency of the face milling of difficult-to-cut materials.
Optimization of Milling Parameters in Face Milling
The objective of this paper is to optimize milling process parameter in case of face milling-Metal removal rate on 6061-T6 Aluminium work-piece using Design of Experiments (DOE) and Response Surface Methodology (RSM) and by taking into consideration feed rate, depth of cut and spindle speed as input parameters.
An Overview on Latest Trend of Face Milling Operation
Milling is one of the widely used methods to remove material from the surface of a job. It employs a milling tool which has multiple number of cutting points and is rotated over the work so as to remove the material. Face Milling, on the other hand, is one of the types of milling process in which the surface from which the material has to be removed is placed perpendicular to the cutter axis. Thus, it is very important to know about the life of the tool as it determines the surface finish of the work. Longer the tool life better is the overall output. Therefore, by selecting different parameters such as process parameter, geometry parameter and machining parameter properly, the life of the tool can be improved. Niranjan Kumar Naulakha | Dipesh Thapa | Sai Kiran Reddy B | N Karthik"An Overview on Latest Trend of Face Milling Operation" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-4 , June 2018...
Development of the Geometry and its Redesigning for a Special Shaped Milling Cutter
2013
This paper presents a shape design methodology to model and improve the geometry of a generic special shaped milling cutter. A dedicated customized tool design modeler is developed to verify the geometry of the cutter. This modeler helps in rendering the proposed three-dimensional parametric definition of the cutter in any CAD modeling environment by suitable translation. The modeled tool is analyzed using finite element analysis to study the cutting insert and the cutter body under transient dynamic load conditions while varying the rake angle of the insert and insert seat. The cutter is redesigned, based on the feedbacks obtained while performing the analysis for the optimum rake angle of the insert. Two different types of special shaped cutters are generated and shown here, from the same definition, to illustrate the generic definition of the special milling cutters.
Effect of Edge Geometry on Cutting Forces in Face Milling with Different Feed Rates
Manufacturing Technology
The fundamental goals of face milling such as high surface quality, dimensional accuracy and productivity can be attained by proper regulation of process parameters, mainly feed rate, depth of cut and cutting speed, but also by taking into consideration the particularities of workpiece material and by selecting the cutting insert with the appropriate geometrical characteristics such as angle κr, rake angle and nose radius. In the present study, the focus is set on the comparison of three different commonly used milling insert types, namely rectangular, round and square regarding cutting forces under various process conditions, with a view to quantitatively evaluate their performance regarding cutting forces and specific cutting forces during face milling of steel workpieces and eventually determine which insert type leads to lower power demand for the same material removed volume. The findings of the present study indicate that the most favorable insert type is the rectangular one, followed by the square and the round one.
Investigation of cutting force in face milling
2017
The increase of cutting applied in finishing processes can be achieved first of all by increasing the cutting speed and feed. In face milling, if feed fz per tooth is increased and/or the shape of the chip cross section is changed, the load of the cutting edges changes and influences the cutting forces and the actual efficiency. In this paper, the cutting force arising in chip removal and changing under the influence of the increased feed is analysed.
Survey of Optimization of Machining Parameters for Face Milling Operation
— The main goal of the manufacturing industry is to manufacture a low/moderate production cost, high quality & better surface finish product in short time. For this achievement a lot of efforts & research work is carried out to determine the optimum parameters such as speed, feed, depth of cut, cutting tool material etc., and their influence is to be studied to obtain better surface finish. Influencing machining parameters may be two, three or four. Wide study was carried out for optimization of machining parameters for face milling operation. Many author designed experiment by using Taguchi method, response surface methodology and factorial design, And used many optimization techniques to optimize the response parameters, like Taguchi, response surface method. Less work carried out on Genetic algorithm technique and ant colony optimization.