Modelling and analysis for the temperature field of the machined surface in the face milling of aluminium alloy

Li, Jiao; Wang, Xibin; Qian, Yubo; Liang, Zhiqiang; Liu, Zhibing

doi:10.1007/s00170-015-7231-y

Cited by 10 publications

(2 citation statements)

References 24 publications

(20 reference statements)

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“…The amount of heat generated in face milling can be high because of the shape of inserts used. It should be noted that almost all cutting power delivered to the system is transferred into heat [ 1 , 2 , 3 ]. Since face milling is often used as the finishing operation, it is responsible for the surface texture and properties.…”

Section: Introductionmentioning

confidence: 99%

Influence of the Cutting Strategy on the Temperature and Surface Flatness of the Workpiece in Face Milling

et al. 2020

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This article analyzes the temperature data obtained for an aluminum alloy face milled using four different cutting strategies. The workpiece temperature was measured at six points with K-type thermocouples. The heat transfer taking place in the cutting zone was also simulated numerically using the finite element method (FEM) and the finite difference method (FDM). The calculation results concerning the distribution of temperature on the workpiece surface were compared with the experimental data. The numerically simulated distribution of temperature on the workpiece surface after face milling was considered in relation to the surface flatness. The findings suggest that the flatness deviations at the workpiece ends were dependent on the depth of cut. Another reason was the cutting strategy selected for the specific thermophysical properties of the workpiece material. Measurement of the workpiece temperature is extremely important because of the thermoelastic behavior and thermal expansion of the material. The isotropic properties of the aluminum alloy make it expand in all directions during milling.

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Section: Introductionmentioning

confidence: 99%

Influence of the Cutting Strategy on the Temperature and Surface Flatness of the Workpiece in Face Milling

et al. 2020

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“…Results indicated that tool wear had a significant impact on the cutting force, cutting temperature, tool wear rate, chip flow and burr formation. Jiao et al 39 carried out a transient 3D simulation to predict the temperature field on the machined surface in single tooth and multi-tooth milling using the FE method.…”

Section: Introductionmentioning

confidence: 99%

Three-dimensional numerical modeling, simulation and experimental validation of milling of a thin-wall component

Bolar

Joshi

2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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Study on mechanics of milling of thin-wall components using a helical end mill is important in view of its complex nature and prominent applications in aerospace, automobile and electronics areas. This article presents a realistic three-dimensional, thermo-structural, finite-element-based mathematical model for thin-wall milling of aerospace grade aluminum alloy. Lagrangian formulation with explicit solution scheme was employed to simulate the interaction between helical milling cutter and the workpiece. Behavior of the material at high strain, strain rate and temperature was defined by Johnson–Cook material constitutive model. Johnson–Cook damage law and friction law were used to account for chip separation and contact interaction. Experimental work was carried out to validate the results predicted by the mathematical model. The developed model predicted the forces in radial, feed and axial directions with errors of 14%, 26% and 33%, respectively. The prediction errors for deflections at top, middle and bottom portions of thin wall were within 11%–39%. The simulated chip dimensions were in good agreement with experimental results while the computed cutting temperature varied by 17% with respect to the experimental value. Overall, it was found that the developed model predicts the process responses with fair and acceptable prediction accuracy. Using the developed model, a study on the effect of process parameters on the performance parameters, namely cutting and thrust forces, stress distribution, cutting temperature, part deflection and chip morphology was carried out, which is not possible using a two-dimensional orthogonal or oblique cutting model. It was found that the developed three-dimensional mathematical model provided very useful insights into the complex physical interaction of helical cutting tool and workpiece during thin-wall milling of aerospace alloys.

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Numerical Modeling and Experimental Validation of Machining of Low-Rigidity Thin-Wall Parts

Bolar

Joshi

2018

Lecture Notes on Multidisciplinary Industrial Engineering

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Modelling and analysis for the temperature field of the machined surface in the face milling of aluminium alloy

Cited by 10 publications

References 24 publications

Influence of the Cutting Strategy on the Temperature and Surface Flatness of the Workpiece in Face Milling

Influence of the Cutting Strategy on the Temperature and Surface Flatness of the Workpiece in Face Milling

Three-dimensional numerical modeling, simulation and experimental validation of milling of a thin-wall component

Numerical Modeling and Experimental Validation of Machining of Low-Rigidity Thin-Wall Parts

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