Determination of minimum uncut chip thickness under various machining conditions during micro-milling of Ti-6Al-4V

Rezaei, Hassan; Sadeghi, Mohammad; Budak, Erhan

doi:10.1007/s00170-017-1329-3

Cited by 46 publications

(12 citation statements)

References 31 publications

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“…There was no reduction in surface roughness at low feed rate values per tooth, f z . One reason was the minimal thickness of the uncut chip [45][46][47][48][49]. The influence of the feed rate on surface condition was not observable in the curves of the graphs (Figs.…”

Section: Determining the Optimal Cutting Parameters (The Fifth Step Omentioning

confidence: 98%

Optimization of cutting conditions using artificial neural networks and the Edgeworth-Pareto method for CNC face-milling operations on high-strength grade-H steel

Abbas

Pimenov

Ердаков

et al. 2019

Int J Adv Manuf Technol

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Computer Numerical Control (CNC) face milling is commonly used to manufacture products from high-strength grade-H steel in both the automotive and the construction industry. The various milling operations for these components have key performance indicators: accuracy, surface roughness (Ra), and machining time for removal of a unit volume min/cm 3 (T m). The specified surface roughness values for machining each component is achieved based on the prototype specifications. However, poor adherence to specifications can result in the rejection of the machined parts, implying extra production costs and raw material wastage. An algorithm using an artificial neural network (ANN) with the Edgeworth-Pareto method is presented in this paper to optimize the cutting parameter in CNC face-milling operations. The set of parameters are adjusted to improve surface roughness and minimal unit-volume material removal rates, thereby reducing production costs and improving accuracy. An ANN algorithm is designed in Matlab, based on a 3-10-1 Multi-Layer Perceptron (MLP), which predicts the Ra of the workpiece surface to an accuracy of ± 5.78% within the range of the experimental angular spindle speed, feed rate, and cutting depth. An unprecedented Pareto frontier for Ra and T m was obtained for the finished grade-H steel workpiece using an ANN algorithm that was then used to determine optimized cutting conditions. Depending on the production objective, one or the other of two sets of optimum machining conditions can be used: the first one sets a minimum cutting power, while the other sets a maximum T m with a slight increase (under 5%) in milling costs.

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Section: Determining the Optimal Cutting Parameters (The Fifth Step Omentioning

confidence: 98%

Optimization of cutting conditions using artificial neural networks and the Edgeworth-Pareto method for CNC face-milling operations on high-strength grade-H steel

Abbas

Pimenov

Ердаков

et al. 2019

Int J Adv Manuf Technol

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“…Also, Biermann et al [41] established that a smaller cutting edge radius causes chatter at small depths of cuts in micromilling because of lower forces. Rezaei et al [21] performed some experiments in Ti6Al4V material using an end mill with cutting diameter of 0.8 mm and average cutting edge radii of 6.089 ± 0.234 μm. Their results indicate the influence of MQL on the reduction of tool wear, and the enlargement of CER, which is caused by a feed rate greater than 2.1 µm/flute.…”

Section: Cutting Forces and Tool Wearmentioning

confidence: 99%

“…13) increases using a feed rate of 2.0 µm/flute, while 2.5 µm/flute resulted with a larger variability between replicates compared with 3.0 µm/flute. Rezaei et al [21] reported that burr formation reduces when feed rate increases, therefore a feed rate of less than 3 µm/ flute causes large burrs which indicates a high portion of ploughing during chip formation. Additionally, cutting edge radius has an influence on cutting forces and surface quality.…”

Section: Cutting Forces and Tool Wearmentioning

confidence: 99%

Evaluation of Ball End Micromilling for Ti6Al4V ELI Microneedles Using a Nanoadditive Under MQL Condition

Celis

Vázquez

Soria-Hernández

et al. 2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

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The use of nanoadditives in lubricants has gained much attention to the research community due to the enhancement of tribological properties and cooling capabilities. This paper studies the advantages of using a MQL (Minimum Quantity of Lubrication) system and nanoadditive in the manufacture of microneedle arrays in Ti6Al4V ELI alloy. Tungsten carbide ball nose tools with a cutting diameter of 200 µm were used in experimental tests. Surface and dimensional characterization was performed to evaluate the impact of a nanoadditive to a vegetable-based oil. Additionally, cutting forces and cutting edge radius (CER) were measured while needles were machined. Experimental tests confirmed that micro end milling with nanoadditives provide slightly better dimensional features and low cutting forces compared to oil. The performance of nanoadditives resulted in a reduction of surface roughness (~ 0.3 μm). Qualitative study of microneedles illustrated burr formation on needle surface manufactured without a nanoadditive solution. Results reveal an increment of CER using low feed rate values (2.0 µm/flute) while a reduction of CER was observed with feed rates up to 2.5 µm/flute. Our results indicated that the addition of nanoadditives to vegetable oil promotes a better product surface topography and cutting tool performance.

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“…The use of an undeformed chip thickness value that is too low in relation to the cutting edge radius r n causes that the material does not undergo cutting but merely ploughing. This phenomenon is highly undesired due to considerable deterioration in workpiece surface condition, which is manifested by the presence of characteristic mill marks [ 10 , 11 ]. Many studies investigate phenomena occurring during the precision milling process conducted with different f z /r n ratios, which makes it possible to examine the transition between ploughing and material cutting [ 10 , 12 , 13 , 14 , 15 , 16 ].…”

Section: Introductionmentioning

confidence: 99%

Dimensional Accuracy and Surface Quality of AZ91D Magnesium Alloy Components after Precision Milling

2021

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This study investigates a precision milling process conducted with the use of conventional end mills and a standard CNC (Computer Numerical Control) machine tool. Milling tests were performed on samples of AZ91D magnesium alloy using TiB2- and TiAlN-coated three-edge end mills measuring 16 mm in diameter. The following technological parameters were made variable: cutting speed, feed per tooth and axial depth of cut. The effects of precision milling were evaluated by analysing the scatter of dimension values obtained in successive tool passes. In addition to that, deviations from the assumed nominal depth as well as obtained ranges of dimension varation were analysed. The study also examined surface quality obtained in the precision milling process, based on the basic surface roughness parameters: Ra, Rz and RSm. Results have confirmed that the use of conventional cutting tools and a standard CNC machine tool makes it possible to manufacture components characterized by relatively small scatter of dimension values and high accuracy classes. Additionally, the results have shown that the type of tool coating and variations of individual technological parameters exert impact on the dimensional accuracy and surface quality obtained.

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Determination of minimum uncut chip thickness under various machining conditions during micro-milling of Ti-6Al-4V

Cited by 46 publications

References 31 publications

Optimization of cutting conditions using artificial neural networks and the Edgeworth-Pareto method for CNC face-milling operations on high-strength grade-H steel

Optimization of cutting conditions using artificial neural networks and the Edgeworth-Pareto method for CNC face-milling operations on high-strength grade-H steel

Evaluation of Ball End Micromilling for Ti6Al4V ELI Microneedles Using a Nanoadditive Under MQL Condition

Dimensional Accuracy and Surface Quality of AZ91D Magnesium Alloy Components after Precision Milling

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