Physical modeling of cast iron radiator nipple oppositely directed thread turn milling

Abstract

The paper covers a single cutter lathe thread turn milling simulation that significantly reduces physical testing costs. The turn milling process involves a synchronized tool (helical mill), and workpiece rotation with a radial oncoming feed through a mill and workpiece relative movement. The cutting rate occurs by the mill teeth movement over the workpiece. The machining depth in each pass varies from zero to the max value, a common milling process feature. The proposed approach simulates the process parameters through thread turning or incomplete circular groove turning of workpieces attached offcenter to a lathe tooling. The proposed turn milling simulation method has reduced the number of machined referenced parts by 710 times. Accordingly, the experimental research period and cost have also been reduced. The research has revealed that the VK6M hard alloy tool life in turn milling with coolant is 50 times longer than the R6M5 HSS tool life while the useful tool life (measured as the number of parts machined within the tool life) for VK6M tools in turn milling with coolant is 50 times higher than that of R6M5 HSS tools. 12. Yan Weilin, Fang Liang, Zheng Zhanguang et al. Effect of surface nanocrystallization on abrasive wear properties in Hadfield steel. Tribology International. 2009. Vol. 42 (5). pp. 634-641. 13. Yan Weilin, Fang Liang, Sun Kun et al. Effect of surface work hardening on wear behavior of Hadfield steel. Materials Science and Engineering A. 2007. 460-461 (4). pp. 542-549. 14. Kolokoltsev V. M., Vdovin K. N., Gorlenko D. A. et al. Calculation of stacking fault energy and its influence on abrasive wear resistance of Hadfield cast steel cooled at different rates. CIS Iron and Steel Review. 2016. Vol. 11. pp. 35-40. 15. Ali Nasajpour, Amir Hossein Kokabi, Parviz Davami et al. Effect of molybdenum on mechanical and abrasive wear properties of coating of as-weld Hadfield steel with flux-cored gas tungsten arc welding.