Optimal Machining Strategy Selection in Ball-End Milling of Hardened Steels for Injection Molds

Buj-Corral, Irene; Ortiz-Marzo, Jose-Antonio; Costa-Herrero, Lluís; Calvet, Joan Vivancos; Luis-Pérez, C.J.

doi:10.3390/ma12060860

Cited by 9 publications

(5 citation statements)

References 25 publications

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“…The surface finish of cams is important, because low roughness reduces friction in the cam-roller contact [27]. Roughness has been measured with a contact profile meter, as is usual in metallic parts with curved surfaces [44]. Shape error is important since better accuracy of the cam profile will favor the compliance with the motion-law of the follower and, consequently, better operation of the mechanism [2].…”

Section: Discussionmentioning

confidence: 99%

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Buj-Corral

Zayas-Figueras

Montaña-Faiget

2020

Metals

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Cam-follower mechanisms are usually employed in different machines, like combustion engines, sewing machines, machine tools, etc. In the present paper, the option to manufacture cams utilizing wire electrical discharge machining (WEDM) has been considered. For this, surface roughness and shape error of cam profiles manufactured by the processes of milling and wire electrical discharge machining (WEDM) are presented. The methodology used covers different stages: design, prototyping, manufacturing, and measurement of the cams. As a reference, a cam-follower mechanism from a motorcycle internal combustion engine has been used. A reverse engineering process has been performed to determine the geometrical parameters of the mechanism, which are used for the synthesis of the profile of the cam and its subsequent design. The manufacturing process of the cams has been assisted by CAD-CAM (Computer Assisted Drawing-Computer Assisted Manufacturing) software. Using fused filament fabrication (FFF), a physical prototype of the cam has been manufactured, in order to validate the goodness of the design. Finally, the roughness and shape parameters have been measured on the contour surface of the cams. The arithmetical mean roughness Ra value of the milled cam was 0.269 μm, below the requirement of 0.4 μm, and shape error was 18 μm, below 50 μm. Shape error of the WEDM cam of 48 μm meets the requirements for cams. However, the Ra value of 1.212 μm, exceeded the limit. For this reason, a finish operation is recommended in this case. Some advantages of WEDM cams over milled cams are that different conductive materials can be employed, more complex shapes can be obtained, and that, in rough operations, the amount of material to be removed in subsequent operations is considerably reduced.

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Section: Discussionmentioning

confidence: 99%

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Buj-Corral

Zayas-Figueras

Montaña-Faiget

2020

Metals

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“…The validation of the proposed models, conducted on the basis of the ANOVA method, proves their applicability to the optimization of aluminum matrix composite manufacturing during the fused deposition modeling assisted by the investment casting. Buj-Corral et al [9] employed a central composite design to model the behavior of surface roughness during ball end milling of hot work-hardened tool steel W-Nr, consisting of a two level factorial design with four factors (24 = 16 experiments), and four central points. The conducted studies have shown that the radial depth of the cut was the most relevant factor on Ra and Rt for both climb and conventional milling.…”

Section: Ofmentioning

confidence: 99%

Advances in Hard–to–Cut Materials: Manufacturing, Properties, Process Mechanics and Evaluation of Surface Integrity

2020

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The rapid growth of a modern industry results in a growing demand for construction materials with excellent operational properties. However, the improved features of these materials can significantly hinder their manufacturing, therefore they can be defined as hard–to–cut. The main difficulties during the manufacturing/processing of hard–to–cut materials are attributed to their high hardness and abrasion resistance, high strength at room or elevated temperatures, increased thermal conductivity, as well as their resistance to oxidation and corrosion. Nowadays the group of hard–to–cut materials includes the metallic materials, composites, as well as ceramics. This special issue, “Advances in Hard–to–Cut Materials: Manufacturing, Properties, Process Mechanics and Evaluation of Surface Integrity” provides a collection of research papers regarding the various problems correlated with hard–to–cut materials. The analysis of these studies reveals primary directions regarding the developments in manufacturing methods, and the characterization and optimization of hard–to–cut materials.

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“…Zhou et al [23] developed a modified grey relational analysis model for optimizing the surface roughness and residual stress in the ball-end milling of Inconel 718. Buj-Corral et al [24] developed an artificial neural network for correlating surface roughness with cutting parameters to obtain the optimal machining strategy in the five-axis ball-end milling of W-Nr. 12344.…”

Section: Introductionmentioning

confidence: 99%

Modelling and Optimization of Machined Surface Topography in Ball-End Milling Process

Wang,

Zhao,

Tan

et al. 2024

Materials

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In order to optimize machined surface topography, this paper presents a novel algorithm for simulating the surface topography and predicting the surface roughness of a ball-end milling process. First, a discrete workpiece model was developed using the Z-map method, and the swept surface of a cutter edge was represented using triangular approximation. The workpiece surface was updated (i.e., material removal process) using the intersection between the vertical reference line and the triangular facet under a cutting judgement. Second, the proposed algorithm was verified by comparing the simulated 3D surface topography as well as 2D surface profile and average roughness (Sa) with experimental measurements. Then, numerical simulation examples planed by the Box–Behnken design methods were carried out to investigate the Sa in the ball-end milling operation. The correlations of Sa and cutting parameters were represented by a response surface reduced quadratic model based on the ANOVA results. Finally, the feed per tooth, radial depth of cut, and tilt and lead angles were optimized for improving the machining efficiency under the Sa constraints. This study presents an effective method for simulating surface topography and predicting the Sa to optimize the cutting parameters during ball-end milling process.

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Optimal Machining Strategy Selection in Ball-End Milling of Hardened Steels for Injection Molds

Cited by 9 publications

References 25 publications

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Comparative Study of Flank Cams Manufactured by WEDM and Milling Processes

Advances in Hard–to–Cut Materials: Manufacturing, Properties, Process Mechanics and Evaluation of Surface Integrity

Modelling and Optimization of Machined Surface Topography in Ball-End Milling Process

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