Surface Roughness and Its Prediction in High Speed Milling of Aluminum Alloys With PCD and Cemented Carbide Tools

Teicher, Uwe; Pirl, Sebastian; Nestler, Andreas; Hellmich, Arvid; Ihlenfeldt, Steffen

doi:10.17973/mmsj.2019_11_2019062

Cited by 7 publications

(5 citation statements)

References 19 publications

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“…Section 5.6) as well as the discontinuous monitoring of tool wear as already discussed in Section 5.3. Nevertheless, there are also approaches pointing in this direction such as the surface roughness models introduced by Bauer et al [77] or Teicher et al [78] as well as the additional surface roughness models from Brammertz [79] or Brown [80]. Either way, the lower resolution range for 3rd -degree shape deviations is currently seen in the magnitude of more than 30 μm, if the calculation is based on the digital shadow data.…”

Section: Surface Qualitymentioning

confidence: 99%

Digital Twins for High-Tech Machining Applications—A Model-Based Analytics-Ready Approach

Hänel

Seidel

Frieß

et al. 2021

JMMP

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This paper presents a brief introduction to competition-driven digital transformation in the machining sector. On this basis, the creation of a digital twin for machining processes is approached firstly using a basic digital twin structure. The latter is sub-grouped into information and data models, specific calculation and process models, all seen from an application-oriented perspective. Moreover, digital shadow and digital twin are embedded in this framework, being discussed in the context of a state-of-the-art literature review. The main part of this paper addresses models for machine and path inaccuracies, material removal and tool engagement, cutting force, process stability, thermal behavior, workpiece and surface properties. Furthermore, these models are superimposed towards an integral digital twin. In addition, the overall context is expanded towards an integral software architecture of a digital twin providing information system. The information system, in turn, ties in with existing forward-oriented planning from operational practice, leading to a significant expansion of the initially presented basic structure for a digital twin. Consequently, a time-stratified data layer platform is introduced to prepare for the resulting shadow-twin transformation loop. Finally, subtasks are defined to assure functional interfaces, model integrability and feedback measures.

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Section: Surface Qualitymentioning

confidence: 99%

Digital Twins for High-Tech Machining Applications—A Model-Based Analytics-Ready Approach

Hänel

Seidel

Frieß

et al. 2021

JMMP

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“…Diamonds are used to prevent edge formation, improve surface quality, and prolong tool lifespan during aluminium alloy machining [8,9]. Numerous studies have investigated and compared how cutting tools made from different materials perform when used to machine aluminium alloys [10][11][12]. Apart from the tool's material, its geometry has a substantial impact on its overall performance and efficiency during machining processes.…”

Section: Introductionmentioning

confidence: 99%

Simulation and Experimental Study of the Termo-Mechanical Effect of the Milling Process of 7075 Aluminium Alloy

Habrat,

Lisowicz,

Tymczyszyn

et al. 2024

Adv. Sci. Technol. Res. J.

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This study combined simulation and experimental tests to analyse the cutting performance of three solid carbide end mills with distinct geometries during the milling of the 7075 aluminium alloy. For the tests, three uncoated end mills were employed, which differed in rake angle, clearance angle, and helical pitch. Simulation tests revealed temperature distributions and the resultant cutting forces. The machining with a milling cutter with a higher blade angle was shown to cause an increase in the temperature in the cutting zone. However, during machining with a sharper blade of cutting tool, a decrease of cutting forces was not observed. The simulated temperature distribution on the cutting edge of the cutting tool may justify significant differences in the dynamics of changes in the cutting force components during the period of operational wear.

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“…As a result, the tool experiences considerable wear, resulting in a shorter lifetime, and the quality of the newly machined surface is compromised [ 5 ]. Especially in the machining of aluminum alloys, this effect becomes relevant [ 6 ].…”

Section: Introductionmentioning

confidence: 99%

Tailored Laser Structuring of Tungsten Carbide Cutting Tools for Improving Their Tribological Performance in Turning Aluminum Alloy Al6061 T6

et al. 2023

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In times of societal development, sustainability has become a major concern for many manufacturers in the metal industries. In this context, surface texturing of cutting tools offers a promising approach in terms of reducing energy consumption and material waste. In this work, direct laser interference patterning is utilized for producing periodic line-like structures with spatial periods of 2.0 µm and 5.5 µm on rake-flank faces of cemented tungsten carbide cutting inserts. Structure depths up to 1.75 µm are reached by controlling the applied number of laser pulses. Turning experiments under lubricated conditions carried out on Al 6061 T6 parts with textured and untreated tools are performed to determine their tribological performances. The used textured cutting tools can effectively decrease machining forces up to 17% due to the corresponding improvement in frictional behavior at the tool/chip interface. Furthermore, the laser-processed tools produce thinner chips and decrease the surface roughness by 31% of the aluminum work piece.

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Surface Roughness and Its Prediction in High Speed Milling of Aluminum Alloys With PCD and Cemented Carbide Tools

Cited by 7 publications

References 19 publications

Digital Twins for High-Tech Machining Applications—A Model-Based Analytics-Ready Approach

Digital Twins for High-Tech Machining Applications—A Model-Based Analytics-Ready Approach

Simulation and Experimental Study of the Termo-Mechanical Effect of the Milling Process of 7075 Aluminium Alloy

Tailored Laser Structuring of Tungsten Carbide Cutting Tools for Improving Their Tribological Performance in Turning Aluminum Alloy Al6061 T6

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