Influence of Cutting Conditions on Tool Life, Tool Wear and Surface Finish in the Face Milling Process

Abstract

The main goal of this work is to study the influence of cutting conditions - cutting speed, feed velocity and feed per tooth - on tool life and surface finish of the workpiece in the face milling of flat surfaces. Aiming to achieve this goal, several milling experiments were carried out with different cutting speeds, feed velocities and feeds per tooth. In the first phase of the experiments, cutting speed was varied without varying feed velocity, which caused a variation in feed per tooth. In the second phase of the experiments, cutting speed and feed velocity were varied in such a way that feed per tooth was kept constant. Tool flank wear and surface roughness of the workpiece were measured as cutting time elapsed. The main conclusions of this work are that a) cutting speed has a strong influence on tool life, regardless of whether feed velocity or feed per tooth varies and b) an increase in surface roughness of the workpiece is not closely related to an increase in wear of the primary cutting edge

Optimization of end milling parameters under minimum quantity lubrication using principal component analysis and grey relational analysis

“…The cutting speed is a highly influencing parameter for surface roughness and tool wear. This is in acceding with beforehand studies on tool wear in turning by Joshi et al (1999), Erol and Ali (2006) and Jenn et al (2008) and milling by Caldeirani and Diniz (2002). Increased abrasion between the cutting tool and work material in the work of higher cutting speed causes higher tool wear and surface roughness.…”

Artificial intelligence for automatic prediction of required surface roughness by monitoring wear on face mill teeth

“…Much of the research devoted to the study of surface roughness in face milling (Diniz and Filho 1999;Caldeirani Filho and Diniz 2002;De Souza et al 2003, 2005De Escalona and Maropoulos 2010;Prasad et al 2011;Houchuan et al 2015;Liu et al 2016;Shi et al 2016;Werda et al 2017) takes tool wear into account. Diniz and Filho (1999) studied the influence of the relative positions of tool and workpiece on tool life, tool wear, and surface finish in the face milling process, taking tool wear into account.…”

“…Diniz and Filho (1999) studied the influence of the relative positions of tool and workpiece on tool life, tool wear, and surface finish in the face milling process, taking tool wear into account. Caldeirani Filho and Diniz (2002) investigated the influence of cutting speed and feed per tooth on tool life and the surface roughness of machined surfaces during mechanical milling, taking into account tool wear. De Souza et al (2003) defined the parameters of surface roughness, Ra, tool life, and burr formation and used them when comparing the performances of two face-milling cutter systems with PCBN (polycrystalline citric boron nitrite) tools.…”

“…Werda et al (2017) compared tool life and surface roughness in the milling of X100CrMoV5 mold steel under different lubrication conditions: dry machining and minimum quantity lubrication (MQL). Even though many authors (Diniz and Filho 1999;Caldeirani Filho and Diniz 2002;De Souza et al 2003, 2005De Escalona and Maropoulos 2010;Prasad et al 2011;Houchuan et al 2015;Liu et al 2016;Shi et al 2016;Werda et al 2017) have presented the results of surface roughness studies that take into account tool wear, no solutions to the problem of how to establish a comprehensive correlation of surface roughness, tool wear, and processing time have been advanced from the perspective of managing these settings in automated production. This task is however made possible with AI.…”

Machinability of Minor Wooden Species before and after Modification with Thermo-Vacuum Technology

“…There are several studies relating wood surface quality and tool sharpness such as [19,20]. However, it is not reported if the thermal modification of wood affects the surface formation mechanisms while cutting with dull tools.…”