Experiment and simulation on the high-speed milling mechanism of aluminum alloy 7050-T7451

Zhang, Ping; Yue, Xiujie; Han, Shuangfeng; Ailing, Song; Li, Baoshun; Xiao, Yu

doi:10.1016/j.vacuum.2020.109778

Cited by 23 publications

(10 citation statements)

References 20 publications

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“…Figure 6 displays the variation of interface pressure, interface temperature, resultant cutting force, and wear rate obtained with a variation in the depth of cut. An increase in interface temperature, interface pressure, and resultant cutting force is observed, and simultaneously a reduction in the wear rate is obtained with an increase in the depth of cut values [39][40][41][42].…”

Section: Resultsmentioning

confidence: 92%

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

Senthilkumar

Hariharan

Tamizharasan

et al. 2022

Advances in Materials Science and Engineering

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In this present work, finite element analysis (FEA)-based simulation of end-milling of AISI1045 steel using tungsten carbide tool was performed using DEFORM-3D simulation software. Usui tool wear model, Johnson-cook material model and adaptive remeshing are considered during machining simulation. The impact of machining variables rate of feed, tool speed, and depth of cut was investigated, and the best integration of variables was distinguished for lower cutting temperature, principal stress, cutting forces, effective stresses, tool wear, and effective strain. The obtained results were correlated using experimentation in a vertical machining center attached with a Kistler tool dynamometer with data acquisition setup for capturing the cutting forces, and an infrared (IR) thermometer was used to measure the cutting temperature, and a comparison was done. Results showed a good correlation. There is a relationship between experimental and numerical results, and simulation findings can be utilised for interpreting the influence of machining parameters.

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Section: Resultsmentioning

confidence: 92%

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

Senthilkumar

Hariharan

Tamizharasan

et al. 2022

Advances in Materials Science and Engineering

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“…Based on high-speed machining (HSM), Wang and Liu [28] studied the acoustic emission signals emitted during chip formation to understand the mechanism behind material separation under the effect of the cutting tool, verifying that serrated chip formation contributes significantly to a greater amplitude of the emitted signal, resulting in continuous and bursting signals being obtained. Ping et al [29] also investigated the HSM of 7050-T7451 alloys, developing a model based on AdvantEdge which, based on traditional milling parameters such as cutting speed, feed, depth of cut, and tool geometry, intended to predict the temperature and forces developed in the tool. Differences in the behavior of the XX' and YY' axes were observed over the machining time, and it was noted that the temperature initially increased but then decreased once a certain cutting speed was reached.…”

Section: Milling Aa750 Aluminum Alloymentioning

confidence: 99%

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Silva,

Martinho,

Magalhães

et al. 2024

JMMP

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Strategies for obtaining deep slots in soft materials can vary significantly. Conventionally, the tool travels along the slot, removing material mainly with the side cutting edges. However, a “plunge milling” strategy is also possible, performing the cut vertically, taking advantage of the tip cutting edges that almost reach the center of the tool. Although both strategies are already commonly used, there is a clear gap in the literature in studies that compare tool wear, surface roughness, and productivity in each case. This paper describes an experimental study comparing the milling of deep slots in AA7050-T7451 aluminum alloy, coated with a novel DLCSiO500W3.5O2 layer to minimize the aluminum adhesion to the tool, using conventional and plunge milling strategies. The main novelty of this paper is to present a broad study regarding different factors involved in machining operations and comparing two distinct strategies using a novel tool coating in the milling of aeronautical aluminum alloy. Tool wear is correlated with the vibrations of the tools in each situation, the cycle time is compared between the cases studied, and the surface roughness of the machined surfaces is analyzed. This study concludes that the cycle time of plunge milling can be about 20% less than that of conventional milling procedures, favoring economic sustainability and modifying the wear observed on the tools. Plunge milling can increase productivity, does not increase tool tip wear, and avoids damaging the side edges of the tool, which can eventually be used for final finishing operations. Therefore, it can be said that the plunge milling strategy improves economic and environmental sustainability as it uses all the cutting edges of the tools in a more balanced way, with less global wear.

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“…In this context, many studies aim to reduce machining time. The main lines for optimization are: enhancing the understanding of cutting phenomena [4][5][6]; improving tool performance [7], selecting the best tools and defining optimal milling parameters [8][9][10], and, finally, enhancing the toolpath geometry [11][12][13].…”

Section: Introductionmentioning

confidence: 99%

Hermite Quartic Splines for Smoothing and Sampling a Roughing Curvilinear Spiral Toolpath

Leroy,

Lavernhe,

Rivière-Lorphèvre

2024

Preprint

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From an industrial point of view, the milling of 2.5D cavities is a frequent operation, 1 consuming time and presenting optimization potential, especially through a judicious choice of 2 the tool trajectory. Among the different types of trajectories, some have a general spiral-like aspect 3 and can potentially offer a reduced machining time. They are called curvilinear trajectories and are 4 obtained by interpolation between structure curves which are the numerical solutions of a partial 5 differential equation. In this case, the machine tool will connect points and the trajectory will be made 6 up of small segments. Even if, macroscopically, these trajectories have all the qualities to allow the 7 tool to move quickly, on a small scale, the discontinuities in tangency, inherent in the discretization, 8 significantly increase machining time. This article suggests to enhancing the continuity level of the 9 toolpath by rebuilding structure curves with a set of Hermite quartic spline patches connected in 10 tangency and curvature. Thanks to this, the tool will machine at an average feedrate closer to the 11 programmed one and will, de facto, reduce traveling time. 12 This article shows that the proposed method increases, on the two tested cavities, toolpath quality 13 indicators, reduces milling time from 10% to 18% for a curvilinear method without a filter and make 14 it possible to generalize the Bieterman and Sandström method for all non convex pockets.

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Experiment and simulation on the high-speed milling mechanism of aluminum alloy 7050-T7451

Cited by 23 publications

References 20 publications

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

A Comparative Study of Different Milling Strategies on Productivity, Tool Wear, Surface Roughness, and Vibration

Hermite Quartic Splines for Smoothing and Sampling a Roughing Curvilinear Spiral Toolpath

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