Experimental study on the effects of cold chamber die casting parameters on high-speed drilling machinability of casted AZ91 alloy

Yazman, Şakir; Köklü, Uğur; Urtekin, Levent; Morkavuk, Sezer; Gemi, Lokman

doi:10.1016/j.jmapro.2020.05.050

Cited by 28 publications

(16 citation statements)

References 39 publications

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“…Though different wear causes, in general, may lead to different wear characteristics of a milling cutter, in high-speed milling the main wear characteristic of ball end mills is governed by flank wear [ 56 , 57 , 58 ], which is also observed as the main wear characteristic in our study, while other wear appearances are not identifiable. Noteworthy, crater wear appears as the second most common wear characteristic at high cutting speeds, occurring at low feed rates [ 59 ].…”

Section: Methodsmentioning

confidence: 72%

Tool Wear and Milling Characteristics for Hybrid Additive Manufacturing Combining Laser Powder Bed Fusion and In Situ High-Speed Milling

et al. 2022

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We report on milling and tool wear characteristics of hybrid additive manufacturing comprising laser powder bed fusion and in situ high-speed milling, a particular process in which the cutter mills inside the powder bed without any cooling lubricant being applicable. Flank wear is found to be the dominant wear characteristic with its temporal evolution over utilization period revealing the typical s-shaped dependence. The flank wear land width is measured by microscopy and correlated to the achievable surface roughness of milled 3D-printed parts, showing that for flank wear levels up to 100 μm a superior surface roughness below 3 μm is accessible for hybrid additive manufacturing. Further, based on this correlation recommended tool, life scenarios can be deduced. In addition, by optimizing the finishing tool start position and the number of afore-built layers, the milling process is improved with respect to the maximum millable angle for undercut surfaces of 3D-printed parts to 30∘ for the roughing process and to 40∘ for the entire machining process including finishing.

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Section: Methodsmentioning

confidence: 72%

Tool Wear and Milling Characteristics for Hybrid Additive Manufacturing Combining Laser Powder Bed Fusion and In Situ High-Speed Milling

et al. 2022

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“…The types of burrs include uniform, transient and crown burrs as shown in Figure 6. Crown burrs are considered as the worst among all due to its irregular shape and need more attention [52,54,55].…”

Section: Analyses Of Hole Qualitymentioning

confidence: 99%

Feasibility of tool configuration and the effect of tool material, and tool geometry in multi-hole simultaneous drilling of Al2024

Aamir

Tolouei‐Rad

Giasin

et al. 2020

Int J Adv Manuf Technol

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“…Additionally, deburring is carried out manually, which reduces productivity [10]. Yazman et al [31] explained three types of burr formation during types of burrs during the drilling process under different drilling parameters, i.e., crown, transient, and uniform burrs. Crown burrs at the exit hole are large, irregular in shape, bend outwards, and considered the worst among all the burr types that need more attention.…”

Section: Burr Formation Analysismentioning

confidence: 99%

Analysis of Hole Quality and Chips Formation in the Dry Drilling Process of Al7075-T6

Habib

Sharif

Hussain

et al. 2021

Metals

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Millions of holes are produced in many industries where efficient drilling is considered the key factor in their success. High-quality holes are possible with the proper selection of drilling process parameters, appropriate tools, and machine setup. This paper deals with the effects of drilling parameters such as spindle speed and feed rate on the chips analysis and the hole quality like surface roughness, hole size, circularity, and burr formation. Al7075-T6 alloy, commonly used in the aerospace industry, was used for the drilling process, and the dry drilling experiments were performed using high-speed steel drill bits. Results have shown that surface roughness decreased with the increase in spindle speed and increased with the increase in the feed rate. The hole size increased with the high spindle speed, whereas the impact of spindle speed on circularity error was found insignificant. Furthermore, short and segmented chips were achieved at a high feed rate and low spindle speed. The percentage contribution of each input parameter on the output drilling parameters was evaluated using analysis of variance (ANOVA).

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Experimental study on the effects of cold chamber die casting parameters on high-speed drilling machinability of casted AZ91 alloy

Cited by 28 publications

References 39 publications

Tool Wear and Milling Characteristics for Hybrid Additive Manufacturing Combining Laser Powder Bed Fusion and In Situ High-Speed Milling

Tool Wear and Milling Characteristics for Hybrid Additive Manufacturing Combining Laser Powder Bed Fusion and In Situ High-Speed Milling

Feasibility of tool configuration and the effect of tool material, and tool geometry in multi-hole simultaneous drilling of Al2024

Analysis of Hole Quality and Chips Formation in the Dry Drilling Process of Al7075-T6

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