Investigation of milling cutting forces and cutting coefficient for aluminum 6060-T6

Tsai, Ming-Yen; Chang, Si Young; Hung, Jui‐Pin; Wang, C.C.

doi:10.1016/j.compeleceng.2015.09.016

Cited by 36 publications

(16 citation statements)

References 16 publications

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“…On the other side, feed rate is decreased with respect to decreasing the chip load. Further, as reported in [7][8][9], cutting force is found to decrease with an increase in spindle speed, while as chip load decreases the cutting force will also decrease. Therefore, increasing spindle speed while decreasing chip load will significantly decrease the cutting force during metal cutting.…”

Section: Introductionsupporting

confidence: 67%

Effect of chip load and spindle speed on cutting force of Hastelloy X

Nor¹,

Baharudin²,

Ghani³

et al. 2020

JMES

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Research on cutting force revealed that the cutting force decreases as cutting speed increases, which is in line with Salomon’s Theory. However, the fundamental behaviour was never clearly explained because most studies had focused on increasing the cutting speed by increasing spindle speed without retaining the rate of chip load. On that note, the effect of increasing spindle speed while chip load is constant on the cutting force of Hastelloy X is presented in this paper. Third Wave AdvantEdge software was applied and half-immersion up-milling simulations were conducted in dry condition. Result showed that the resultant force was primarily affected by the axial force, followed by normal force and feed force. Trend-lines indicated that the behaviour of cutting force components and resultant force was quadratic. Desirability Function Analysis (DFA) results revealed that the optimum combination of chip load and spindle speed led to lowest cutting force components and resultant force was at 0.013 mm/tooth and 24,100 RPM. Furthermore, the optimum cutting conditions that led to the lowest cutting force components and resultant force at chip loads of 0.016 mm/tooth and 0.019 mm/tooth was 24,100 RPM also. Therefore, increasing Material Removal Rate (MRR) while minimizing cutting force components and resultant force can be achieved by increasing the amount of chip load at spindle speed of 24,100 RPM.

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Section: Introductionsupporting

confidence: 67%

Effect of chip load and spindle speed on cutting force of Hastelloy X

Nor¹,

Baharudin²,

Ghani³

et al. 2020

JMES

View full text Add to dashboard Cite

show abstract

“…On this basis, Adam et al [184] extracted the cutting force coefficient of aluminum alloy al6061-t6511 by average force and optimization technology methods. Tsai et al [185] studied the effects of feed rate per tooth and tool diameter on cutting force and cutting coefficient. On this basis, the cutting parameters, including friction angle and shear stress, are estimated using oblique cutting theory.…”

Section: Identification Methods Based On Measured Milling Forcementioning

confidence: 99%

Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

Duan

Ding

et al. 2021

Chin. J. Mech. Eng.

153

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Aluminum alloy is the main structural material of aircraft, launch vehicle, spaceship, and space station and is processed by milling. However, tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy. The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters, material mechanical properties, machine tools, and other parameters. In particular, milling force is the crucial factor to determine material removal and workpiece surface integrity. However, establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system. The research progress of cutting force model is reviewed from three modeling methods: empirical model, finite element simulation, and instantaneous milling force model. The problems of cutting force modeling are also determined. In view of these problems, the future work direction is proposed in the following four aspects: (1) high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth, which easily produces high residual stress. The residual stress should be analyzed under this particular condition. (2) Multiple factors (e.g., eccentric swing milling parameters, lubrication conditions, tools, tool and workpiece deformation, and size effect) should be considered comprehensively when modeling instantaneous milling forces, especially for micro milling and complex surface machining. (3) The database of milling force model, including the corresponding workpiece materials, working condition, cutting tools (geometric figures and coatings), and other parameters, should be established. (4) The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling. (5) The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication (mql) and nanofluid mql should be predicted.

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“…As previously mentioned, cutting force knowledge can help understand the process's details and enable its optimization and understanding, being of great use on machining cases of hard-to-machine materials. Regarding the prediction of cutting forces in the milling process, in the study developed by Tsai et al [36], two methods of predicting the cutting force for the milling of Al 6060-T6 alloy are presented. These methods are as follows: Altintas and recursive least square (RLS).…”

Section: Cutting Force Prediction Methodsmentioning

confidence: 99%

Cutting Forces Assessment in CNC Machining Processes: A Critical Review

Sousa

Silva

Fecheira

et al. 2020

Sensors

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Machining processes remain an unavoidable technique in the production of high-precision parts. Tool behavior is of the utmost importance in machining productivity and costs. Tool performance can be assessed by the roughness left on the machined surfaces, as well as of the forces developed during the process. There are various techniques to determine these cutting forces, such as cutting force prediction or measurement, using dynamometers and other sensor systems. This technique has often been used by numerous researchers in this area. This paper aims to give a review of the different techniques and devices for measuring the forces developed for machining processes, allowing a quick perception of the advantages and limitations of each technique, through the literature research carried out, using recently published works.

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Investigation of milling cutting forces and cutting coefficient for aluminum 6060-T6

Cited by 36 publications

References 16 publications

Effect of chip load and spindle speed on cutting force of Hastelloy X

Effect of chip load and spindle speed on cutting force of Hastelloy X

Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

Cutting Forces Assessment in CNC Machining Processes: A Critical Review

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