Effect of Different Cooling Strategies on Surface Quality and Power Consumption in Finishing End Milling of Stainless Steel 316

Abbas, Adel T.; Anwar, Saqib; Abdelnasser, Elshaimaa; Luqman, Monis; Qudeiri, Jaber Abu; Elkaseer, Ahmed

doi:10.3390/ma14040903

Cited by 21 publications

(12 citation statements)

References 32 publications

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“…A lot of research works have been devoted to the analysis and optimisation of cutting process parameters to achieve low surface roughness levels [36][37][38], high dimensional accuracy [39], high process efficiency [40,41] and reduced energy consumption during the machining process [42]. Many previous works have also been devoted to different strategies for implementing cooling and lubrication of the cutting process of aluminium alloys and their effect on the surface quality after machining [43,44]. Maruda et al [45] presented a study on the effect of minimum quantity lubrication and surface roughness in the turning process.…”

Section: Introductionmentioning

confidence: 99%

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

et al. 2021

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Lightweight alloys made from aluminium are used to manufacture cars, trains and planes. The main parts most often manufactured from thin sheets requiring the use of milling in the manufacturing process are front panels for control systems, housing parts for electrical and electronic components. As a result of the final phase of the manufacturing process, cold rolling, residual stresses remain in the surface layers, which can influence the cutting processes carried out on these materials. The main aim of this study was to verify whether the strategy of removing the outer material layers of aluminium alloy sheets affects the surface roughness after the face milling process. EN AW-6082-T6 aluminium alloy thin plates with three different thicknesses and with two directions relative to the cold rolling process direction (longitudinal and transverse) were analysed. Three different strategies for removing the outer layers of the material by face milling were considered. Noticeable differences in surface roughness 2D and 3D parameters were found among all machining strategies and for both rolling directions, but these differences were not statistically significant. The lowest values of Ra = 0.34 µm were measured for the S#3 strategy, which asymmetrically removed material from both sides of the plate (main and back), for an 8-mm-thick plate in the transverse rolling direction. The highest values of Ra = 0.48 µm were measured for a 6-mm-thick plate milled with the S#2 strategy, which symmetrically removed material from both sides of the plate, in the longitudinal rolling direction. However, the position of the face cutter axis during the machining process was observed to have a significant effect on the surface roughness. A higher surface roughness was measured in the areas of the tool point transition from the up-milling direction to the down-milling direction (tool axis path) for all analysed strategies (Ra = 0.63–0.68 µm). The best values were obtained for the up-milling direction, but in the area of the smooth execution of the process (Ra = 0.26–0.29 µm), not in the area of the blade entry into the material. A similar relationship was obtained for analysed medians of the arithmetic mean height (Sa) and the root-mean-square height (Sq). However, in the case of the S#3 strategy, the spreads of results were the lowest.

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Section: Introductionmentioning

confidence: 99%

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

et al. 2021

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“…On the other hand, in terms of cutting technology, there are respectively: peripheral milling, end milling, and face milling. The selection of a proper milling variant has a significant impact on the cutting forces [ 2 ], temperature [ 3 , 4 ], the dynamics of the milling process, chip formation, as well as the quality of a surface after milling [ 5 , 6 , 7 ]. Figure 1 presents the types of milling along with the direction of a resultant cutting force.…”

Section: Introductionmentioning

confidence: 99%

High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude

et al. 2021

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High feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the high feed milling (HFM), experimental tests were conducted, preceded by an analysis of cutting zones when milling with an HF face cutter. The face milling tests of 42CrMo4 steel with the use of an HF cutter characterized by an entering angle, dependent on axial depth of cut ap and insert radius r values, as well as with a conventional face cutter with the entering angle of 45° were performed. The study focused on analyzing the vibration amplitude, cutting force components in the workpiece coordinate system, and surface roughness. The experimental tests proved, that when milling with constant cut layer thickness, the high feed cutter allowed to obtain twice the cutting volume in comparison with the conventional face cutter. However, higher machining efficiency resulted in an increase in cutting force components. Furthermore, the results indicate significantly higher surface roughness and higher vibration amplitudes when milling with the HF cutter.

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“…Some different approaches to the cooling the cutting area can be found in literature as well. The authors of [18] investigated the way the cooling strategy can influence some aspects of cutting technologies, like power consumption or the roughness of the surface machined by the end milling of a certain material. A strategy of optimizing the cooling performance by using three coolant jets is presented in [19].…”

Section: Introductionmentioning

confidence: 99%

A Fully Symmetrical High Performance Modular Milling Cutter

et al. 2021

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Milling cutters belong to a widely used category of cutting tools. In this category, modular milling cutters are a narrow niche, less studied, and developed. Usually, they are symmetrical cutting tools. A milling cutting tool that can be reconfigured due to its modularity and still keeps its symmetry becomes more interesting and useful for machining. The paper presents such a new concept in a computer aided design (CAD) model of a cutting tool based on some novel features. The tool itself is designed as a modular complex. The way the torque is transmitted from the shaft to the elementary cutters is an original one, as they are joined together based on a profiled assembling. The profile is one formed of filleted circular sectors and segments. The reaming of the elementary cutters has two sections each of them assuming a task: transmitting the torque, and precisely centring, respectively. The cooling system, which is a component of the tool, provides the cutting area with coolant both on the front and side face of the cutting tool. Some nozzles placed around the cutting tool send jets or curtains of coolant towards the side surface of the cutter, instead of parallel, as some existing solutions do. The source of the coolant supply is the inner cooling system of the machine tool. This provides the tool with coolant having proper features: high enough flow and pressure. The output of the research is a CAD-based model of the modular milling cutter with a high performance cooling system. All of this model’s elements were designed taking into account the design for manufacturing principles, so it will be possible to easily manufacture this tool. Several variants of milling cutters obtained by reconfiguring the complex tool are presented. Even if the tool is usually a symmetric complex, it can process asymmetric parts. Symmetry is intensively used to add some advantages to the modular cutting tool: balanced forces in the cutting process, the possibility of controlling the direction of the axial cutting force, and a good machinability of the grooves used to assemble the main parts of the cutting tool.

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Effect of Different Cooling Strategies on Surface Quality and Power Consumption in Finishing End Milling of Stainless Steel 316

Cited by 21 publications

References 32 publications

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude

A Fully Symmetrical High Performance Modular Milling Cutter

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