Surface topography characterization in finish milling

Elbestawi, M.A.; Ismail, F.; Yuen, K.M.

doi:10.1016/0890-6955(94)90104-x

Cited by 53 publications

(21 citation statements)

References 11 publications

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“…A fine-milled surface is typically machined using small depth of cut, low cutting speed and feed [10]. Finish milling often only relates to optimising the topography, for example explored by Elbestawi et al who investigated end milling of a AISI 1020 steel [11]. However, the finish machined surface is of great importance in other aspects as well since it sets the final surface quality related to residual stresses, hardness and alterations in the microstructure.…”

Section: General Notionsmentioning

confidence: 99%

Surface integrity after post processing of EDM processed Inconel 718 shaft

Holmberg

Wretland

Berglund

et al. 2017

Int J Adv Manuf Technol

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Electrical discharge machining (EDM) is considered as an efficient alternative to conventional material removal concepts that allows for much higher material removal rates. However, EDM generates unwanted features such as re-cast layer (RCL), tensile residual stresses and a rough surface. In order to recover the surface integrity, different post processes has been compared: high-pressure water jet (HPWJ), grit blasting (GB) and shot peening (SP). Surface integrity has been evaluated regarding microstructure, residual stresses, chemical content and surface roughness. The results showed that a combination of two post processes is required in order to restore an EDM processed surface of discontinuous islands of RCL. HPWJ was superior for removing RCL closely followed by grit blasting. However, grit blasting showed embedded grit blasting abrasive into the surface. Regarding surface roughness, it was shown that both grit blasting and HPWJ caused a roughening of the surface topography while shot peening generates a comparably smoother surface. All three post processes showed compressive residual stresses in the surface where shot peening generated the highest amplitude and penetration depths. However, the microstructure close to the surface revealed that shot peening had generated cracks parallel to the surface. The results strongly state how important it is to evaluate the surface at each of the different subsequent process steps in order to avoid initiation of cracks.

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Section: General Notionsmentioning

confidence: 99%

Surface integrity after post processing of EDM processed Inconel 718 shaft

Holmberg

Wretland

Berglund

et al. 2017

Int J Adv Manuf Technol

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“…6,7 During machining, the mill axis is substantially perpendicular to the machined surface, we take three positions of the axis of the milling cutter in order to optimize the quality of the surface state, reducing the applied load to the machine tool and save operation of other machine tools. Indeed, we note that the signatures of the milling cutter on the surface state have changed during the machining in the three positions of the axis of the milling machine.…”

Section: Defining the Problemmentioning

confidence: 99%

“…Nevertheless, the majority of the research related to the surface roughness generated in the spherical end milling, focuses only on a geometric kinematic basic model. 5,6 For this reason, this work contains the analysis of the surface roughness generated in vertical milling including the deviation of the angle of perpendicularity with respect to the surface shortness and minimum thickness. The single direction of upward vertical tool orientation was deliberately selected to demonstrate a better understanding of how to obtain an optimum machined surface.…”

Section: Introductionmentioning

confidence: 99%

Geometric analysis of the influence of perpendicularity of a spindle axis of the milling machine on the surface quality

Bloul

Bourdim

Hamou

et al. 2017

Advances in Mechanical Engineering

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This paper deals with analyzes of the influence of the perpendicularity of the spindle of the milling machine on the machined surface. This is part of the geometric errors of machine tools and in a direct manner constitutes a defect on the quality of the workpiece. Therefore, the surface roughness is particularly sensitive to the cutting speed, the feed rate, round of teeth default, the tool tip radius and the cutter teeth number. This article examines the characteristics of the surface topography of steel parts, in finishing machining using milling cutters. The study is conducted by computer simulation tests and experimental part using surface condition monitoring instruments, taking into consideration the round teeth default. The variation of the inclination of the spindle of the milling machine in three positions (90°+ 30#, 90°, and 90°-30#) shows a good agreement between the simulation and the experimental results for sharp and moderately worn tools. Similarly, this study showed that the presented model could thus be integrated into systems computer-aided design and computer-aided manufacturing. Finally, the physical and statistical parameters of roughness during milling at position 90°confirmed that, when the defect of the perpendicularity is eliminated to the maximum, the best surface conditions are obtained.

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“…In the second step, we include the surface roughness with run-out and the surface roughness with the relative vibration between the tool and the workpiece as expressed by Eqs. (13) and (14) [28][29][30].…”

Section: High Feed Milling Of the Workpiece Clamped By The Asymmetricmentioning

confidence: 97%