Correlating surface roughness, tool wear and tool vibration in the milling process of hardened steel using long slender tools

Aguiar, Marcelo Mendes de; Diniz, Anselmo Eduardo; Pederiva, Robson

doi:10.1016/j.ijmachtools.2013.01.002

Cited by 74 publications

(31 citation statements)

References 34 publications

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“…They presented various techniques including analytical as well as experimental to avoid chatter and select machining parameters, viz., depth of cut and spindle speed to achieve maximum chatter free MRR. Aguiar et al (2013) presented a correlation between surface roughness, tool wear and tool vibration in the milling process of hardened steel using long slender tools. They concluded that, wear was not the problem for the tools since, even after long cutting time (400 min), flank wear was very slight and surface roughness of the work-piece did not increased significantly with cutting time.…”

Section: Literature Reviewmentioning

confidence: 99%

Identification of Stability Lobe Diagram for Milling Using Vibration Analysis

N.S¹,

S.S²,

G.V³

2015

Int. Jour. Des. Manf. Tech.

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-Chatter is a self-excited vibrations. Increased working speeds of machining produces excitation of oscillations and cause dynamic problems. Chatter reduces the tool life, produces poor surface finish, reduces productivity and increases rejections. The experiments performed in this experimental work describes the method for obtaining stability lobe diagram for milling operations and this to help operator in selecting combination of input cutting parameters, viz., depth of cut and spindle speed for chatter free machining. Vibration analysis technique is used for these experiments. Experiments are carried out on vertical milling machine and vibrations signals are acquired using accelerometer. AA-6061 material is used for workpiece. The results obtained shows that, vibration analysis is simple, easy and efficient method for obtaining stability lobe diagram which helps operator to select combination of input parameters, viz., spindle speed and depth of cut for chatter free maximum material removal rate.

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Section: Literature Reviewmentioning

confidence: 99%

Identification of Stability Lobe Diagram for Milling Using Vibration Analysis

N.S¹,

S.S²,

G.V³

2015

Int. Jour. Des. Manf. Tech.

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“…In parallel to this study, Asilturk and Neseli 10 worked on the multi-response optimization of CNC turning parameters via a Taguchi-method-based response-surface analysis. M. M. De Aguiar et al 11 investigated the correlating surface roughness, tool wear and tool vibration in the milling process of hardened steel using long slender tools. In this study, a good workpiece-surface roughness together with a long tool life of long tools with small diameters was achieved.…”

Section: Introductionmentioning

confidence: 99%

Effects of cutting parameters and tool-path strategies on tool acceleration in ball-end milling

Gök¹,

Gök²,

Bilgin³

et al. 2017

Mater. Tehnol.

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The determination of the cutting-parameter values that cause increases in vibration values is important to minimize the errors that can occur. Thus, the first aim of this study was to investigate the optimum cutting-parameter values and tool-path strategies in ball-end milling of the EN X40CrMoV5-1 tool steel with three coated cutters using the Taguchi method. The parameters taken into consideration are the cutting speed, feed rate, step over and tool-path strategies. The second aim of the study, a model for the tool acceleration as a function of the cutting parameters, was obtained using the response-surface methodology (RSM). As a result, the most effective parameter within the selected cutting parameters and cutting strategies for both inclined surfaces and different coatings was the step over. In terms of tool coatings, the most deteriorating coating for the tool acceleration on both inclined surfaces was the TiC coating. In addition, the response-surface methodology is employed to predict the tool-vibration values depending on the cutting parameters and tool-path strategy. The model generated gives highly accurate results. Keywords: inclined surfaces, ball-end milling, tool acceleration, Taguchi method, response-surface methodology, response optimization Neoptimalni rezalni parametri med mehansko obdelavo lahko povzro~ijo ne`elene vibracije in posledi~no napake. Prvi cilj avtorjev te {tudije je bil dolo~iti optimalne vrednosti rezalnih parametrov in strategije potovanja orodja med mehansko obdelavo orodnega jekla EN X40CrMoV5-1 s krogli~nim frezalom s tremi rezili z razli~no prevleko (TiC, TiN in TiAlN). Za to so uporabili Taguchi-jevo metodo. Parametri, ki so jih avtorji zajeli v {tudiji so bili: hitrost rezanja, velikost odvzema, korak odvzema (preskok) in strategija poti orodja. Drugi cilj avtorjev te {tudije je bil izdelati model pospe{evanja orodja v odvisnosti od rezalnih parametrov, z uporabo metodologije odziva povr{ine (angl. RSM). Ugotovili so, da je korak odvzema (angl.: step over) naju~inkovitej{i parameter med izbranimi rezalnimi parametri in rezalnimi strategijami, tako za oba izbrana nagiba (ukrivljenosti) povr{ine, kot tudi izbrane trde prevleke. Med izbranimi trdimi prevlekami se je v vseh pogojih frezanja kot najslab{a izkazala TiC prevleka. RSM metodologija dodatno omogo~a napoved vibracij orodja v odvisnosti od rezalnih parametrov in izbrane strategije poti orodja. Izdelani model daje zelo to~ne rezultate. Klju~ne besede: nagib (ukrivljenost) povr{ine, mehanska obdelava s krogli~nim frezalom, pospe{ek orodja, Taguchi metoda, metodologija odgovora povr{ine, optimizacija odgovora

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“…These tools are frequently required for the manufacturing of parts with deep pockets and relatively thin ribs. The researches carried out by Tlusty et al [17] and Mendes de Aguiar et al [18] show that the appropriate selection of milling parameters together with the tool slenderness can improve the material removal rate and surface finish. Nevertheless, the direct relations between the ball end mill's slenderness, its dynamical (modal) parameters and the instantaneous tool deflections generated during precise milling are still insufficiently recognized.…”

Section: Introductionmentioning

confidence: 99%

The study on dynamic properties of monolithic ball end mills with various slenderness

et al. 2017

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Abstract. The reliable determination of modal mass, damping and stiffness coefficient (modal parameters) for the particular machine-toolholder-tool system is essential for the accurate estimation of vibrations, stability and thus the machined surface finish formed during the milling process. Therefore, this paper focuses on the analysis of ball end mill's dynamical properties. The tools investigated during this study are monolithic ball end mills with different slenderness values, made of coated cemented carbide. These kinds of tools are very often applied during the precise milling of curvilinear surfaces. The research program included the impulse test carried out for the investigated tools clamped in the hydraulic toolholder. The obtained modal parameters were further applied in the developed tool's instantaneous deflection model, in order to estimate the tool's working part vibrations during precise milling. The application of the proposed dynamics model involved also the determination of instantaneous cutting forces on the basis of the mechanistic approach. The research revealed that ball end mill's slenderness can be considered as an important milling dynamics and machined surface quality indicator.

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Correlating surface roughness, tool wear and tool vibration in the milling process of hardened steel using long slender tools

Cited by 74 publications

References 34 publications

Identification of Stability Lobe Diagram for Milling Using Vibration Analysis

Identification of Stability Lobe Diagram for Milling Using Vibration Analysis

Effects of cutting parameters and tool-path strategies on tool acceleration in ball-end milling

The study on dynamic properties of monolithic ball end mills with various slenderness

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