A sustainability comparison between drilling and milling for hole-enlargement in machining of hardened steels

Iqbal, Asif; Suhaimi, Hazwani; He, Ning

doi:10.1080/10910344.2019.1575409

Cited by 7 publications

(3 citation statements)

References 18 publications

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“…Holes can be machined by drilling, milling, electrical discharge machining, etc. Unfortunately, it is impractical to drill the hole with large diameter [1] . Electrical discharge machining has no macroscopic cutting force, and it is not limited by material hardness, therefore, electrical discharge becomes one of the mainstream technologies for machining super-hard materials [2] .…”

Section: Introductionmentioning

confidence: 99%

An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling

Han,

Gu,

et al. 2023

Int J Adv Manuf Technol

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The machining time is mainly related to the tool path and the corresponding feed speed, while the trochoidal tool path depends on the trochoidal step and trochoidal radius. The material removal rate is periodically distributed along the tool path in trochoidal milling a hole. But more than half of tool paths do not cut material in trochoidal milling a hole, so a constant feed speed in milling a hole will limit the machining efficiency. In this paper, a trochoidal radius optimization approach is presented to improve the efficiency of trochoidal milling a hole, which considering the optimal feed speed. Firstly, the mathematical representation of the trochoidal radius is formulated by analyzing the generation principle of trochoidal path, so the trochoidal radius could be determined under the premise of the hole diameter, maximum uncut radial material and the tool diameter are fixed. Furthermore, the trochoidal radius optimization model， which based on the adjusted feed speed, is established with the goal of minimizing the machining time. Secondly, an adaptive feed speed scheduling strategy for trochoidal milling is proposed, which is constrained by stable material removal rate and adjusted by a cubic polynomial algorithm. Finally, taking a hole machining as an example, simulation and experimental results show that the efficiency of applying the trochoid milling method proposed has increased by 13.8% compared to traditional helix milling method.

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Section: Introductionmentioning

confidence: 99%

An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling

Han,

Gu,

et al. 2023

Int J Adv Manuf Technol

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“…The drilling process accounts for 40% of all metal machining operations and is an inevitable process for assembly operations. 21,22 Although the machinability of magnesium alloys is easy due to low hardness and Young's modulus, 23 it is reported that some problems such as ignition depending on the chip size and built-up edge may occur during machining which complicates the process and affects hole quality. 24–26 In order to avoid such problems and to obtain higher quality holes, it is necessary to machine materials produced with different processes and using appropriate parameters, tools, and conditions.…”

Section: Introductionmentioning

confidence: 99%

Influence of extrusion parameters on drilling machinability of AZ31 magnesium alloy

Köklü

Koçar

Morkavuk

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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AZ31 magnesium alloy is mainly used in aerospace applications due to its lightweight and good mechanical properties. The installation of AZ31 alloy in an aircraft usually requires machining operations such as drilling and milling for assembly purposes. The current study aims to investigate the effects of different extrusion ratios (1.77, 2.68, 3.55) on the drilling machinability of AZ31 alloys. The machinability was evaluated with thrust force, borehole surface quality, and chip characteristics. It was found that the thrust force and hole quality depend on the extrusion ratio and cutting parameters. The highest thrust force and surface roughness Ra occurred when drilling AZ31 alloy produced using the highest extrusion ratio of 3.55 in agreement with the improvement in the mechanical properties. The chip length decreased with the increase of the extrusion ratio depending on a decrease in the ductility, while SEM images showed that the AZ31 sample produced using intermediate extrusion ratio had the best hole edge quality and least burr formation.

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“…Yip et al presented a quantification approach for the evaluation of triple bottom line of machining sustainability in ultraprecision machining of titanium alloys [ 5 ]. Machining sustainability is generally quantified in terms of tool life, specific energy consumption, processing cost, material removal rate, work surface quality, and amount of swarf generated [ 3 , 6 ]. Regarding the milling of Ti–6Al–4V, the effect of cutting speed on temperature is more prominent than those of feed rate and depth of cut [ 7 ].…”

Section: Introductionmentioning

confidence: 99%

On Coolant Flow Rate-Cutting Speed Trade-Off for Sustainability in Cryogenic Milling of Ti–6Al–4V

et al. 2021

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Application of cryogenic fluids for efficient heat dissipation is gradually becoming part and parcel of titanium machining. Not much research is done to establish the minimum quantity of a cryogenic fluid required to sustain a machining process with respect to a given material removal rate. This article presents an experimental investigation for quantifying the sustainability of milling a commonly used titanium alloy (Ti–6Al–4V) by varying mass flow rates of two kinds of cryogenic coolants at various levels of cutting speed. The three cooling options tested are dry (no coolant), evaporative cryogenic coolant (liquid nitrogen), and throttle cryogenic coolant (compressed carbon dioxide gas). The milling sustainability is quantified in terms of the following metrics: tool damage, fluid cost, specific cutting energy, work surface roughness, and productivity. Dry milling carried out the at the highest level of cutting speed yielded the worst results regarding tool damage and surface roughness. Likewise, the evaporative coolant applied with the highest flow rate and at the lowest cutting speed was the worst performer with respect to energy consumption. From a holistic perspective, the throttle cryogenic coolant applied at the highest levels of mass flow rate and cutting speed stood out to be the most sustainable option.

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A sustainability comparison between drilling and milling for hole-enlargement in machining of hardened steels

Cited by 7 publications

References 18 publications

An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling

An optimization method of trochoidal radius for trochoidal milling hole based on the adaptive feed rate scheduling

Influence of extrusion parameters on drilling machinability of AZ31 magnesium alloy

On Coolant Flow Rate-Cutting Speed Trade-Off for Sustainability in Cryogenic Milling of Ti–6Al–4V

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