Numerical and experimental study of the drilling of multi-stacks made of titanium alloy Ti-6Al-4V: interface and burr behavior

Glaa, Nawel; Mehdi, Kamel; Moussaoui, Kamel; Zitoune, Rédouane

doi:10.1007/s00170-020-05116-0

Cited by 4 publications

(3 citation statements)

References 39 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The most important analysis focused on increasing the credibility of durability assessment was the determination of the "general intensity of the vibration intensity of the system". Specification of "intensity" had to take into account the vibro-diagnostic changes of the experimental system to determine the needed machining factors, since any change in spindle rotation (due to the required cutting speeds) considerably affects the frequency range that is interconnected with the tool wear rate and manifested in the machining characteristics [51].…”

Section: The Influence Of Tool Wear and Cutting Speed On The Intensit...mentioning

confidence: 99%

Effect of Wear on Vibration Amplitude and Chip Shape Characteristics during Machining of Eco-Friendly and Leaded Brass Alloys

Monka

Monková

Pantazopoulos³

et al. 2023

Metals

View full text Add to dashboard Cite

The dynamic stability of the machining set and the entire cutting process, together with the appropriate form of chips generated during machining under the given conditions, are the basic prerequisites for autonomous machining in accordance with the Industry 4.0 trend. The research, based on a newly designed method, aims to study the frequency response of the machining system to different values of tool wear and cutting speed, which cause the worsening of the machined parts’ quality and the instability of the whole cutting process. The new idea is based on the inverse principle, in which the wear with various values of VB was artificially prepared in advance before machining. Consequently, the effect of artificial wear and cutting speed on vibration and chip shape characteristics were studied. Three types of brass alloys were used within the experiments as the machined materials. Measured data were statistically processed and the desired dependencies were plotted. Chips were collected for each combination of machining conditions, while the article presents a database of the obtained chip shapes at individual cutting speeds so that they can be compared and classified. The results showed that brass alloys CW510L and CW614N exhibit an average of three times lower vibration damping compared to the CW724R alloy, while relatively good chip formation was noted in the evaluated machining conditions even without the use of a chip breaker. The problematic chip shape occurred only in some cases at the machining of CW510L and CW724R, which cannot be generalized.

show abstract

Section: The Influence Of Tool Wear and Cutting Speed On The Intensit...mentioning

confidence: 99%

Effect of Wear on Vibration Amplitude and Chip Shape Characteristics during Machining of Eco-Friendly and Leaded Brass Alloys

Monka

Monková

Pantazopoulos³

et al. 2023

Metals

View full text Add to dashboard Cite

show abstract

“…In the preparatory phase of the research, the milling cutters were modelled in Solid Edge® software, and their machining behaviour was simulated in Simulia-ABAQUS® using the FEM. The method assisted to design a tool geometry, to evaluate the cutter behaviour at machining and to improve its geometry by minimizing von Mises stress [33,34].…”

Section: Newly Designed Milling Cuttersmentioning

confidence: 99%

Optimal cutting parameter specification of newly designed milling tools based on the frequency monitoring

Monka

Monková

Majstorovic

et al. 2020

Int J Adv Manuf Technol

View full text Add to dashboard Cite

The article deals with the specification of the most suitable machining parameters for three newly designed end mills in the term of stability of the deep groove machining, at which the depth of cut is minimally twice higher the diameter of the cutter. Online vibration analysis was selected as a tool for goal achievement. The partial objective of the first phase of experimental research was to set the boundary conditions of vibrodiagnostics at the specification of the behaviour of three commercially produced milling cutters when the results were compared with the surface roughness achieved at the machining with individual cutting parameters. Vibrodiagnostic conditions were subsequently applied in the second phase of the experiment to determine the most suitable machining parameters of newly designed milling cutters. The Pinnacle VMC 650 CNC machining centre with Fanuc control system was used to perform the experiments. The material of cutters was S-grade sintered carbide, and all the designed cutters were PVD coated with the same AlTiN (aluminium titanium nitride) coating. The machined material was 16MnCr5 (1.7131) steel. The surface roughness analysis after machining by newly designed cutters pointed out that they are better as for the surface quality in comparison with the commercially produced end mills. Finally, it was possible to state that the four-tooth cutter 01-FVT with helix angles (β1= 39° and β2 = 41°) and tooth pitch (τ1 = 83° and τ2 = 97°) seems to be the best tool for milling deepshaped grooves among all the tested milling cutters.

show abstract

“…Several results have been obtained, such as the prediction of chip formation and the study of its morphology [17,18]. Likewise, other models have been developed to predict cutting forces and heat transfers during machining [19][20][21][22] or the influence of these parameters on the morphology of the chip [23]. This paper deals with the dynamic behavior of thin walled workpieces made of steel alloy 42CrMo4 during roughing and finishing turning process.…”

Section: Introductionmentioning

confidence: 99%

Numerical and Experimental Investigation on Dynamic Behavior in Turning Process of Thin-walled Workpieces made of 42CrMo4 Steel Alloy

Sahraoui

Glaa

Mehdi

2021

Preprint

Self Cite

View full text Add to dashboard Cite

Machining thin-walled parts is generally cumbersome due to their low structural rigidity. Thus, to better understand the dynamic behavior of thin-walled parts during machining, various engineers and researchers in the field of metal cutting employ the Finite Element Method (FEM) due to its ability to highlight the physics involved in chip formation and the range of force generated in the cutting zone. The results of numerical simulations are evaluated using comparison with experimental data. In this paper, we study the effect of feed rate as well as the thickness of the wall part made of 42CrMo4 steel alloy on the cutting forces and workpiece displacements both experimentally and numerically during roughing and finishing turning process. The numerical study is based on the development of a three-dimensional (3D) Finite Element Model (FEM) in Abaqus/Explicit frame. In the model, the workpiece material is governed by a behavior law of Johnson-Cook. The detachment of the chip is simulated by a ductile fracture law also of Johnson-Cook. Numerical and experimental results show that the cutting forces and the quality of the machined surface depend not only on the choice of cutting parameters but also on the dynamic behavior of thin-walled parts due to their low rigidity and low structural damping during of the machining operation. Indeed, cutting forces are proportional to the feed rate and inversely proportional to the thickness of the part. The largest displacements recorded on the part are mainly along the direction of the tangential component of the cutting force. The flexibility of the part generates instability in the cutting process, but the frequencies of the vibrations are higher than the frequency of rotation of the part.

show abstract

Numerical and experimental study of the drilling of multi-stacks made of titanium alloy Ti-6Al-4V: interface and burr behavior

Cited by 4 publications

References 39 publications

Effect of Wear on Vibration Amplitude and Chip Shape Characteristics during Machining of Eco-Friendly and Leaded Brass Alloys

Effect of Wear on Vibration Amplitude and Chip Shape Characteristics during Machining of Eco-Friendly and Leaded Brass Alloys

Optimal cutting parameter specification of newly designed milling tools based on the frequency monitoring

Numerical and Experimental Investigation on Dynamic Behavior in Turning Process of Thin-walled Workpieces made of 42CrMo4 Steel Alloy

Contact Info

Product

Resources

About