Cutting Forces and Roughness During Ball End Milling of Inclined Surfaces

Gimadeev, M. R.; Stelmakov, V. A.; Gusliakov, V. V.

doi:10.1007/978-3-030-54817-9_107

Cited by 5 publications

(5 citation statements)

References 13 publications

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“…The cutting force can be mainly divided into F Z (in the vertical direction) and F XY (the combined cutting force of F X and F Y in the horizontal direction). Existing research indicates that the F Z acts primarily downward when cutting the curved surface 29 . Therefore, the F Z instead inhibits the material on the milled surface from buckling upward to form a delamination burr.…”

Section: Experiments and Resultsmentioning

confidence: 99%

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Study of the interlayer bonding strength for combined 3D printing and milling of polyetheretherketone

Zhou

Cheng

Jiang³

et al. 2023

J of Applied Polymer Sci

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Polyetheretherketone (PEEK) has good mechanical properties and biocompatibility for a wide range of biomedical applications. The combined 3D printing and milling process (CPMP) is a typical additive/subtractive hybrid manufacturing technique, which facilitates the rapid response for customized PEEK implants. This paper investigates the CPMP process combining fused deposition modeling printing and dry milling for PEEK materials. The results show that the bending and shearing effects of the milling cutter on the 3D-printed part cause the machined surface to be extremely susceptible to delamination. Poor Z-direction interlayer bonding strength at the 3D printing stage is the main cause of delamination. Therefore, the effects of 3D printing parameters (nozzle temperature, layer thickness, and bed temperature) on Z-direction interlayer bonding strength are studied using an orthogonal experiment design method. The applicability of three 3D printing infill patterns (grid, rectilinear, and gyroid) in CPMP is compared.The results of the research show that the storage modulus is a more accurate reflection of the interlayer bonding strength in the Z-direction than the shear strength. With a combination of parameters of a nozzle temperature of 450 C, a layer thickness of 0.1 mm, a bed temperature of 260 C and a rectilinear infill pattern, the 3D-printed parts have significantly stronger interlayer bonding strength.Consequently, there exists almost no delamination on the milled surface.

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Section: Experiments and Resultsmentioning

confidence: 99%

“…Existing research indicates that the F Z acts primarily downward when cutting the curved surface. 29 Therefore, the F Z instead inhibits the material on the milled surface from buckling upward to form a delamination burr. Hence, the effect of the F Z on the bonding interlayer is not the primary cause of delamination.…”

Section: Results and Analysismentioning

confidence: 99%

Study of the interlayer bonding strength for combined 3D printing and milling of polyetheretherketone

Zhou

Cheng

Jiang³

et al. 2023

J of Applied Polymer Sci

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“…1. Схема для определения: а -сил резания сфероцилиндрической фрезы; б -срезаемого сегмента; в -площади поперечного сечения приведенной фигуры [16].…”

Section: машиностроение и машиноведениеunclassified

“…где ch -гиперболический косинус, th -гиперболический тангенс. Для определения бесконечно малой длины режущей кромки можно воспользоваться выражением, предложенным в [7,16,19]:…”

Section: машиностроение и машиноведениеunclassified

“…8. Срезаемый при механообработке сегмент 2: а -вид сверху; б -проекция срезаемого сегмента [16] Уточним, что инструмент режет в зоне 2. Полученные данные подтверждаются результатами моделирования, но рассмотрены для идеального случая.…”

Section: машиностроение и машиноведение а) б)unclassified

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Analysis of automated surface roughness parameter support systems based on dynamic monitoring

Gimadeev

2022

Vestnik Donskogo gosudarstvennogo tehničeskogo universiteta

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Introduction. Domestic and foreign works on the milling of complex-profile surfaces with a ball-end tool were analyzed. Methods of surface quality control and ways to provide amplitude parameters of roughness, based on research data and field experiments, were considered. Theoretical provisions on the determination of cutting forces and the results of vibroacoustic diagnostics were presented.Materials and Methods. The methods of correlation analysis, comparison and generalization of the results were applied. The data were calculated at different tool angles, taking into account the instantaneous cutting forces, and were fixed in the range of values of the variable feed per tooth (fz) and the angle of inclination of the surface (γ). The vibroacoustic diagnostic data and theoretical data of the presented model at different tool inclination angles were verified by experiment. Consequently, such methods can be used to predict surface roughness parameters.Results. The relationship between cutting forces, tool inclination angle, and vibroacoustic diagnostics data was found. A model of the cutting force and tool displacements was formulated taking into account the inclination of the surface. The optimal range of the inclination angle of the tool to the surface to be machined, at which the minimum values of the amplitude parameters of roughness were achieved, was determined. The sound vibrations obtained empirically, presented in spectral and wave forms, were in good agreement with data from other sources. This allowed us to conclude about the feasibility of forecasting and monitoring roughness parameters in real time through acoustics.Discussion and Conclusions. It was established that the growth of forces in the direction ae(X) and fz(Y) was observed at γ > 40°. This was due to the distribution of the components of the cutting force along the cutting edge and depended on the inclination of the surface. The amplitude parameters decreased when the angle increased from 10 to 40 degrees. The found interrelations of force analysis, processing directions, and vibroacoustic diagnostics have validated the use of vibroacoustic diagnostics to predict surface roughness. Acoustic diagnostics, regardless of the layout of technological equipment, enables to quickly adjust the sound device and assess the impact of cutting modes on roughness parameters.

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Tool Condition Monitoring Techniques for Milling

Gimadeev

2023

Lecture Notes in Mechanical Engineering

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Cutting Forces and Roughness During Ball End Milling of Inclined Surfaces

Cited by 5 publications

References 13 publications

Study of the interlayer bonding strength for combined 3D printing and milling of polyetheretherketone

Study of the interlayer bonding strength for combined 3D printing and milling of polyetheretherketone

Analysis of automated surface roughness parameter support systems based on dynamic monitoring

Tool Condition Monitoring Techniques for Milling

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