High-speed face milling of AZ91 Mg alloy: Surface integrity investigations

Marakini, Vikas; Pai, P. Srinivasa; Bhat, K. Udaya; Thakur, Dinesh Singh; Achar, Bhaskara P.

doi:10.1016/j.ijlmm.2022.06.006

Cited by 9 publications

(2 citation statements)

References 49 publications

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“…As shown in Figure 6, there was a common tendency for machined surface roughness variation with the feed-per-tooth value. Usually, at lower values of this parameter, the machined surface quality is better than that obtained at higher values of feed per tooth [45,46]. This tendency was observed for both 100 m/min and 125 m/min in the tests conducted at a 5 m cutting length.…”

Section: Machined Surface Roughness Analysismentioning

confidence: 83%

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Wear Behavior Phenomena of TiN/TiAlN HiPIMS PVD-Coated Tools on Milling Inconel 718

Sousa

Fernandes

Silva

et al. 2023

Metals

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Due to Inconel 718’s high mechanical properties, even at higher temperatures, tendency to work-harden, and low thermal conductivity, this alloy is considered hard to machine. The machining of this alloy causes high amounts of tool wear, leading to its premature failure. There seems to be a gap in the literature, particularly regarding milling and finishing operations applied to Inconel 718 parts. In the present study, the wear behavior of multilayered PVD HiPIMS (High-power impulse magnetron sputtering)-coated TiN/TiAlN end-mills used for finishing operations on Inconel 718 is evaluated, aiming to establish/expand the understanding of the wear behavior of coated tools when machining these alloys. Different machining parameters, such as cutting speed, cutting length, and feed per tooth, are tested, evaluating the influence of these parameters’ variations on tool wear. The sustained wear was evaluated using SEM (Scanning electron microscope) analysis, characterizing the tools’ wear and identifying the predominant wear mechanisms. The machined surface was also evaluated after each machining test, establishing a relationship between the tools’ wear and production quality. It was noticed that the feed rate parameter exerted the most influence on the tools’ production quality, while the cutting speed mostly impacted the tools’ wear. The main wear mechanisms identified were abrasion, material adhesion, cratering, and adhesive wear. The findings of this study might prove useful for future research conducted on this topic, either optimization studies or studies on the simulation of the milling of Inconel alloys, such as the one presented here.

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Section: Machined Surface Roughness Analysismentioning

confidence: 83%

“…Apart from tool wear, it was noticed that machining parameters clearly influenced the machined surface's quality, especially the feed per tooth (fz) parameter [45]. In Figure 6, the obtained results regarding the machined surface roughness for the various test parameters can be observed.…”

Section: Machined Surface Roughness Analysismentioning

confidence: 93%

Wear Behavior Phenomena of TiN/TiAlN HiPIMS PVD-Coated Tools on Milling Inconel 718

Sousa

Fernandes

Silva

et al. 2023

Metals

View full text Add to dashboard Cite

show abstract

Kinematics and improved surface roughness model in milling

Liu

Dong

et al. 2022

Int J Adv Manuf Technol

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Implications of stress concentrators and work hardening in flat tensile samples subjected to milling and abrasive water jet machining

Buglioni,

Krahmer,

Sánchez Egea

et al. 2024

Int J Adv Manuf Technol

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The milling process is the standard method for producing flat tensile test specimens from sheet metal. However, alternative methods employed in the industry for cutting sheet metal include abrasive water jet cutting, laser cutting, punching, and, to a lesser extent, electrical discharge machining. Among these, abrasive water jet cutting stands out for its superior material integrity, versatility, precision, and efficiency, making it a preferred choice. Previous studies consistently show that specimens cut by abrasive water jetting exhibit lower ultimate tensile strength and higher percent elongation than those obtained by milling in standardized tensile tests. This study investigates this behavior across different types of steel and alloys. Both steel types were subjected to milling and water jetting processes, followed by an analysis of their experimental and simulated mechanical behavior to identify discrepancies between the two methods. The findings suggest that milling, influenced by factors such as feed per tooth and cutter diameter, introduces geometric stress concentrators. This relative increase in ultimate tensile strength and decrease in percent elongation are observed consistently in milled tensile specimens compared to those cut by water jet, regardless of material type or thickness. Additionally, the effects of perimeter hardening resulting from superficial plastic deformation caused by the cutting edge, likely due to its small thickness, do not influence the observed trends significantly.

show abstract

High-speed face milling of AZ91 Mg alloy: Surface integrity investigations

Cited by 9 publications

References 49 publications

Wear Behavior Phenomena of TiN/TiAlN HiPIMS PVD-Coated Tools on Milling Inconel 718

Wear Behavior Phenomena of TiN/TiAlN HiPIMS PVD-Coated Tools on Milling Inconel 718

Kinematics and improved surface roughness model in milling

Implications of stress concentrators and work hardening in flat tensile samples subjected to milling and abrasive water jet machining

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