Model Design and Optimization of Carbide Milling Cutter for Milling Operation of M200 Tool Steel

Phokobye, Solomon Ntshiniki; Daniyan, Ilesanmi; Tlhabadira, Isaac; Masu, Leonard; VanStaden, L.R.

doi:10.1016/j.procir.2019.04.300

Cited by 21 publications

(10 citation statements)

References 19 publications

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“…As previously stated, tool geometry influences the machining processes and, nowadays, has more complex geometries. There have been recent studies on the design of tools in order to improve the machining processes, such as the study performed by Phokobye et al [25] that proposed a design and optimization of a carbide milling cutter for the milling of M200 tool steel. The model was designed based on Finite Element Analysis (FEA) using Autodesk software Fusion 360.…”

Section: Introductionmentioning

confidence: 99%

Recent Advances on Coated Milling Tool Technology—A Comprehensive Review

Sousa

Silva

2020

Coatings

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The milling process is one of the most used processes in the manufacturing industry. Milling, as a process, as evolved, with new machines and methods being employed, in order to obtain the best results consistently. Milling tools have also seen quite an evolution, from the uncoated high-speed steel tool, to the now vastly used, coated tools. Information on the use of these coated tools in recent scientific researches was collected. The coatings that are currently being researched are going to be presented, highlighting some novel advances in the nanocomposite and diamond coatings area, as these coatings are seeing a growing use in the industry, with very satisfactory results, with performance and tool-life increase. Wear mechanism of various types of coatings are also a popular topic on recent research, as the cutting behavior of these coated tools provides valuable information on the tool’s-life. Furthermore, analysis of these mechanisms enables for the selection of the best coating type for the correct application. Recently, the employment of coated tools paired with sustainable lubrication methods as seen some use. As this presents the opportunity to enhance the coated tool’s and the process’s performance, obtaining better results, in terms of better tool-life and better surface finish quality, in a more sustainable fashion.

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Section: Introductionmentioning

confidence: 99%

Recent Advances on Coated Milling Tool Technology—A Comprehensive Review

Sousa

Silva

2020

Coatings

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“…The effectiveness of the coolants within a small area of the work piece may account for a significant reduction in the magnitude of the cutting temperature at the shear zone. The findings indicate that the process parameters and machining conditions are key parameters, which influence the rate of machinability, degree of surface finish as well as process economics and sustainability, hence the need for an effective process design and control [39,40].…”

Section: No /mentioning

confidence: 99%

DEVELOPMENT OF NUMERICAL MODELS FOR THE PREDICTION OF TEMPERATURE AND SURFACE ROUGHNESS DURING THE MACHINING OPERATION OF TITANIUM ALLOY (Ti6Al14V)

et al. 2020

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Temperature and surface roughness are important factors, which determine the degree of machinability and the performance of both the cutting tool and the work piece material. In this study, numerical models obtained from the Response Surface Methodology (RSM) and Artificial Neural Network (ANN) techniques were used for predicting the magnitude of the temperature and surface roughness during the machining operation of titanium alloy (Ti6Al4V). The design of the numerical experiment was carried out using the Response Surface Methodology (RSM) for the combination of the process parameters while the Artificial Neural Network (ANN) with 3 input layers, 10 sigmoid hidden neurons and 3 linear output neurons were employed for the prediction of the values of temperature. The ANN was iteratively trained using the Levenberg-Marquardt backpropagation algorithm. The physical experiments were carried out using a DMU80monoBLOCK Deckel Maho 5-axis CNC milling machine with a maximum spindle speed of 18 000 rpm. A carbide-cutting insert (RCKT1204MO-PM S40T) was used for the machining operation. A professional infrared video thermometer with an LCD display and camera function (MT 696) with infrared temperature range of −50−1000 °C, was employed for the temperature measurement while the surface roughness of the work pieces were measured using the Mitutoyo SJ – 201, surface roughness machine. The results obtained indicate that there is high degree of agreement between the values of temperature and surface roughness measured from the physical experiments and the predicted values obtained using the ANN and RSM. This signifies that the developed RSM and ANN models are highly suitable for predictive purposes. This work can find application in the production and manufacturing industries especially for the control, optimization and process monitoring of process parameters.

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“…This means that analyzing cutting force data can provide a way to monitor the machining process or even identify certain aspects of it, which can be improved. The knowledge of these cutting forces can be used to monitor tool behavior [ 39 , 40 ] and to provide information on optimal machining parameters [ 41 , 42 ], because selecting these parameters the machining process is improved. There are two main methods of determining cutting forces, using a direct or indirect approach; however, the most employed method is a direct one using a dynamometer to measure these forces.…”

Section: Introductionmentioning

confidence: 99%

Wear Behavior and Machining Performance of TiAlSiN-Coated Tools Obtained by dc MS and HiPIMS: A Comparative Study

et al. 2021

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Duplex stainless steels are being used on applications that require high corrosion resistance and excellent mechanical properties, such as the naval and oil-gas exploration industry. The components employed in these industries are usually obtained by machining; however, these alloys have low machinability when compared to conventional stainless steels, usually requiring the employment of tool coatings. In the present work, a comparative study of TiAlSiN coating performance obtained by these two techniques in the milling of duplex stainless-steel alloy LDX 2101 was carried out. These coatings were obtained by the conventional direct current magnetron sputtering (dc MS) and the novel high power impulse magnetron sputtering (HiPIMS). The coatings were analyzed and characterized, determining mechanical properties for both coatings, registering slightly higher mechanical properties for the HiPIMS-obtained coating. Machining tests were performed with varying cutting length and feed-rate, while maintaining constant values for axial and radial depth of cut and cutting speed. The surface roughness of the material after machining was assessed, as well as the wear sustained by each of the tool types, identifying the wear mechanisms and behavior of these tools, as well as registering the flank wear values presented for each of the tested tools. The HiPIMS-obtained coating exhibited a very similar behavior when compared to the other, producing similar surface roughness quality. However, the HiPIMS coating exhibited less wear for higher cutting lengths, proving to be a better choice in this case, especially regarding tool life.

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Model Design and Optimization of Carbide Milling Cutter for Milling Operation of M200 Tool Steel

Cited by 21 publications

References 19 publications

Recent Advances on Coated Milling Tool Technology—A Comprehensive Review

Recent Advances on Coated Milling Tool Technology—A Comprehensive Review

DEVELOPMENT OF NUMERICAL MODELS FOR THE PREDICTION OF TEMPERATURE AND SURFACE ROUGHNESS DURING THE MACHINING OPERATION OF TITANIUM ALLOY (Ti6Al14V)

Wear Behavior and Machining Performance of TiAlSiN-Coated Tools Obtained by dc MS and HiPIMS: A Comparative Study

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