The aim of this study was to improve the machinability of wood-plastic composites by exploring the effects of different wood-plastic composites on machinability. In particular, the effects of milling with cemented carbide cutters were assessed by investigating cutting forces, cutting temperature, surface quality, chip formation, and tool wear. The cutting parameters determined to yield an optimal surface quality were rake angle 2°, cutting speed 9.0 m/s, feed per tooth 0.3 mm, and cutting depth 1.5 mm. In these optimized milling conditions, the wood-plastic composite with polypropylene exhibited the highest cutting forces, cutting temperature, and tool wear, followed by polyethylene and polyvinyl chloride wood-plastic composites. Two wear patterns were determined during wood-plastic composite machining, namely chipping and flaking. Due to the different material composition, semi-discontinuous ribbon chips and continuous ribbon chips were generated from the machining process of wood-plastic composites with polypropylene and polyethylene, respectively. The wood-plastic composite with polyvinyl chloride, on the other hand, formed needle-like chips. These results contribute to a theoretical and practical basis for improved wood-plastic composite machining in industrial settings.
In order to meet the requirements of cutting efficiency and economy in the processing of stone plastic composite, milling tests of the stone plastic composite were conducted using straight tooth diamond tools. Cutting forces and temperature were measured under different cutting parameters. Response surface methodology was used to analyze the variation of cutting forces and temperature and to determine the significant contribution of each variable and its two‐level interaction. The correlation between actual and predicted results was found by building mathematical models of cutting forces and temperatures, which can be used to make accurate predictions. At last, the optimal cutting parameters for stone plastic composite straight‐tooth milling with low cutting forces and cutting temperatures were found to be 10° front angle, 37.9 m/s cutting speed, 0.32 mm feed per tooth, and 0.5 mm milling depth. It is possible to improve processing efficiency and reduce production costs by using these parameters in industrial processing.
To improve the cutting quality of stone-plastic composites, a series of milling experiments were performed using the response surface, binary, and microanalysis methodologies, paying special attention to the effects of milling parameters (rake angle from 6°to 14°, spindle speed from 5000 rpm to 7000 rpm, feed rate from 10 m/min to 20 m/min, and milling depth from 0.5 mm to 2 mm) on the quality of the machined surface. Surface damage was mainly concentrated on the crest and two axial sides of the milling wave, with cracking and pitting identified as the main damage patterns. These experiments determined that the optimal conditions for milling stone-plastic composite with minimal surface roughness are a rake angle of 10°, cutting speed of 37.9 m/s, feed per tooth of 0.32 mm, and milling depth of 0.5 mm. The mathematical model for surface roughness developed from these results is highly reliable and could be used for the prediction and optimization of surface roughness during industrial manufacturing of stone-plastic composites.
This work focused on changes in surface roughness under different cutting conditions for improving the cutting quality of beech wood during milling. A response surface methodology and an adaptive network-based fuzzy inference system were adopted to model and establish the relationship between milling conditions and surface roughness. Moreover, the significant impact of each factor and two-factor interactions on surface roughness were explored by analysis of variance. The specific objective of this work was to find milling parameters for minimum surface roughness, and the optimal milling condition was determined to be a rake angle of 15°, a spindle speed of 3357 r/min and a depth of cut of 0.62 mm. These parameters are suggested to be used in actual machining of beech wood with respect of smoothness surface.
This project aims to improve the machinability of wood-plastic composites by understanding chip and built-up edge formation, so as to help manufacturers optimize cutting performance and product quality. Chip formation and built-up edge were studied during orthogonal cutting of wood polyethylene composite with cemented carbide cutters under different conditions. During the orthogonal cutting process, segmental, ribbon, and element chips were generated. The cutting depth was found to have a great impact on the types of chips that formed. Additionally, a built-up edge was found during wood-plastic composite machining, with debris only attaching to the tool's rake face due to thermo-mechanical coupling. Such built-up edges hinder cutting stability and surface quality. Furthermore, variations in the accumulation of debris on the built-up edge corresponded to changes in cutting force and temperature. In fact, both cutting force and temperature proved to be inversely related to the rake angle and positively correlated to the cutting speed and depth. Therefore, to achieve better cutting stability and surface quality for wood-plastic composites, a larger rake angle and a reduced cutting depth are recommended because they reduce the accumulation of debris and the formation of built-up edge.
This study provides guidelines for the industrial machining of wood-plastic composites, focusing on their behaviour under friction, specifically when friction is caused by sliding contact with cemented carbide. Using the response surface method (RSM) to explore the correlation between the friction coefficient and the wood-plastic composite type, loading force, and reciprocating frequency, a series of frictional tests were performed. The significant contributions of each factor and their twofactor interactions were determined by analysis of variance (ANOVA), with a significance level of 5%, while trends in the variation of the friction coefficient were investigated by using a response surface methodology. The wood-plastic composite types had the greatest impact on the friction coefficient, followed by loading force and reciprocating frequency. A mathematical model (CoF = −0.10was developed to accurately predict changes in the friction coefficient during machining of such composites. According to the results of the optimisation, wood-plastic composite with polypropylene should be machined with high-speed cutting, whereas those with polyethylene and polyvinyl chloride are recommended for low-speed machining, so as to ensure the lowest friction coefficient.
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