Single and multi-objective optimization for cutting force and surface roughness in peripheral milling of Ti6Al4V using fixed and variable helix angle tools

Sur, Gökhan; Motorcu, Ali Rıza; Nohutçu, Samet

doi:10.1016/j.jmapro.2022.06.016

Cited by 26 publications

(10 citation statements)

References 36 publications

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Section: Resultssupporting

confidence: 64%

“…Only considering the influence of f, the surface roughness analysis results in Figure 9 are in accordance with the result of Equation ( 3). The feeding rate has the greatest influence on the surface roughness, and the other studies have yielded similar results [39][40][41]. In order to eliminate the influence of diameters of Tool A and Tool B on surface roughness, relative surface roughness is introduced, marked as M, and the calculation is as follows:…”

Section: Surface Roughnessmentioning

confidence: 98%

See 1 more Smart Citation

Study on Characteristics for Reaming Titanium Alloy Ti6Al4V with Two Kinds of Cemented-Carbide Groove Reamers

Zhang

Wang

Han³

2022

Materials

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Titanium alloys have been extensively used in practical machining owing to their outstanding mechanical properties, high specific strength and low thermal deformation. In this study, the cutting experiments are carried out on Ti6Al4V material with right-hand and straight cemented-carbide groove reamers. The experimental results show that the cutting force with the right-hand reamer is smaller compared to straight groove reamer due to the groove structure. The main tool wear forms are micro-chipping, adhesive wear, abrasive wear, and coating falling off on the right-hand reamer, while there is a built-up edge and serious damage failure on the cutting edge of the straight groove reamer. Notch wear and pitting on the surface of the hole wall are mainly caused by chip adhesion and tool wear. The surface-roughness value is the lowest as the cutting speed is 60 m/min and the feed rate is 0.4 mm/rev. The holes machined by the right-hand reamer have a low hole diameter deviation with various cutting parameters. The geometric accuracy of cylindricity is higher as the feed rate is 0.4 mm/rev and the cutting speed is 40 m/min for both kinds of reamers, and the cylindricity is better with the right-hand reamer.

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Section: Resultssupporting

confidence: 64%

Section: Surface Roughnessmentioning

confidence: 98%

Study on Characteristics for Reaming Titanium Alloy Ti6Al4V with Two Kinds of Cemented-Carbide Groove Reamers

Zhang

Wang

Han³

2022

Materials

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show abstract

“…In milling, the single most used criterion is the maximum absolute value of the cutting force. [3][4][5] This value is easy to determine, correlates well with tool life and is equal for both stationary and rotating force measurement systems. This leaves a big part of the information in the raw force signal unused.…”

Section: Introductionmentioning

confidence: 92%

“…The tool and workpiece were flooded with a general purpose, high performance neat oil (Blaser Swisslube, Blasomill 22). Blasomill 22 is a high performance cutting oil based on mineral oil with a viscosity of 22 mm 2 /s and a density of 0.85 g/cm 3 .…”

Section: Model Calibrationmentioning

confidence: 99%

The Influence of the Metalworking Fluid on Tool Wear in Milling Inconel 718

Meier¹,

Eglin²

2023

Proceedings of the Institution of Mechanical Engineers, Part J:

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The understanding of tool wear mechanisms is fundamental to developing more productive machining processes. Therefore, the influence of different metalworking fluids on tool wear is studied when milling Inconel 718 using a rotating dynamometer, a stationary dynamometer, and a 3D microscope. A newly developed force model allows the interpretation of more than the maximal cutting force and explains the relation between tribological conditions, tool wear and process forces. In a novel setup, the coolant type was changed in the middle of the tool life to differentiate the direct influence of the coolant on the process forces and the indirect effect via tool wear. By fitting the model to the data, it is found that the metalworking fluid and the process parameters not only influence the wear rate globally, but also lead to different wear mechanisms. The 3D data of worn cutting edges confirms the existence of different wear mechanisms.

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“…As an effective approach to processing hard and brittle materials, ultrasonic vibration-assisted machining (UVAM) can reduce the cutting force in the machining process and improve the machining quality and tool life by applying high-frequency vibration to the tool in the machining process [6]. During the machining process, the cutting force has a direct impact on the material removal process [7,8], tool life [9,10], and surface integrity [11,12]. By predicting and adjusting the cutting force in the processing, machining efficiency and quality can be improved by optimizing related parameters.…”

Section: Introductionmentioning

confidence: 99%

Modeling for Ultrasonic Vibration-assisted Helical Grinding of SiC particle-reinforced Al-MMCs

Li¹,

Yuan

Gao³

et al. 2023

Preprint

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Silicon carbide (SiC) particle-reinforced aluminum matrix (SiCp/Al) composites have continuously increased applications in abundant industries due to their superior mechanical properties. However, such composites have issues achieving desired machinability and quality standard due to the presence of SiC particles which is the main hindrance to their applications. In this paper, the methodology of ultrasonic vibration-assisted helical grinding (UVHG) of SiCp/Al composites has been applied to achieve to desired quality and efficiency for such composites. Then a mechanical cutting force model was developed to predict grinding forces. The grinding force was separated into friction force, plastic deformation force, and fracture force on account of the material removal mechanism. The undeformed chip thickness and cross-sectional area were calculated for the grinding force of a single diamond abrasive grit and then extended to the whole tool. By considering the acoustic softening effect of reduction of deformation stress caused by ultrasonic vibration, the acoustic softening coefficient was first proposed in the model to correct the impact of the ultrasonic vibration for properties of SiCp/Al composites. The experimental machining (UVHG) was carried out considering the different groups of experiments. The experimental results found agreed with the predicted values of cutting forces. The prediction deviation of the model was 7.06%, which could provide further guidance for the grinding process optimization of SiCp/Al composites. The novel cutting force predicted model and proposed machining methodology could be applied to machining SiCp/Al composites at the industry level and further research work.

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Single and multi-objective optimization for cutting force and surface roughness in peripheral milling of Ti6Al4V using fixed and variable helix angle tools

Cited by 26 publications

References 36 publications

Study on Characteristics for Reaming Titanium Alloy Ti6Al4V with Two Kinds of Cemented-Carbide Groove Reamers

Study on Characteristics for Reaming Titanium Alloy Ti6Al4V with Two Kinds of Cemented-Carbide Groove Reamers

The Influence of the Metalworking Fluid on Tool Wear in Milling Inconel 718

Modeling for Ultrasonic Vibration-assisted Helical Grinding of SiC particle-reinforced Al-MMCs

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