Effect of machine tool’s spindle forced vibrations on surface roughness, dimensional accuracy, and tool wear in vertical milling of AISI P20

Environmentally conscious machining of Inconel 718: surface roughness, tool wear, and material removal rate assessment

“…As far as feed rate (ƒ z ) is concerned, the effect of ƒ z is an anticipated behavior which is consistent with other studies [5,19]. In a previous study, Zahoor et al [5] found that the machine spindle-force vibrations and ƒ z are the most effective parameters for R a during the milling of AISI P20 tool steel. It is attributed to a milling phenomenon in which the high ƒ z increases the distance between the two consecutive cuts leaving some uncut material behind on the workpiece surface which deteriorates the surface finish.…”

“…The calculated V B for all nine trials is given in Table 5. It is noted from the table that flank wear in each test is less than the standard tool life criteria (ISO 8688-2) for milling [5]. The maximum (V B 101.5 m) and minimum (V B 8.95 m) tool wear are achieved at 10 passes of 630 mm distance and at 15 passes of 945 mm distance, respectively.…”

“…Despite the aforecited advantages, machinability of Ni-alloys is challenging for manufacturers due to their low thermal conductivity and high work-hardening characteristics [3][4]. Although, conventional machining of these advanced materials has an edge over non-conventional cutting methods in terms of low machining cost and high production rate [5][6], in the quest for achieving high productivity and quality of the machined surface, the tool life significantly suffers. The machining of these alloys involves an excessive amount of heat that cannot effectively be dissipated due to their low heat conductivity.…”

Experimental investigation of the microhardness and surface roughness of a pressure-die-casted A413 alloy on milling using the desirability approach

“…The diesel engine heads were fabricated using a horizontal pressure die-casting machine (120T technocrat) under an optimal solution. 23 The standard short sleeve is coupled with the maximum shot capacity for aluminium of 6.9 kg. A locking force with 400 t capacity inbuilt in the setup and an electric furnace provided with maximum capacity of melting temperature 2000°C with 1000 L capacity.…”

“…It is known that in the turning operation where tool is continuously having contact with the workpiece, but in milling, the machining operation is focused to be intermittent, wherein the milling cutter engages and disengages, alternatively, with the workpiece. 23 Also, sudden engagement with the lower cutting speed, which gives chances of more contact between the work-tool interfaces, causes scratches on the workpiece shown in Figure 10a, so applying a higher cutting speed will enhance the quality of the final component. Above the nominal feed rate value, it produced aggressive feed marks, shown in Figure 10b.…”