The effect of the cutting edge helix angle of the cutter on the process of chips removing from the cutting zone

Burek, Jan; Żyłka, Łukasz; Płodzień, Marcin; Sułkowicz, Paweł; Buk, Jarosław

doi:10.17814/mechanik.2017.11.152

Cited by 5 publications

(6 citation statements)

References 4 publications

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“…The plots of volume fraction at different time steps show that in the tool electrodes with helix angles 25°to 45°the volume fraction of debris decreases in each successive time-step. For the single-helical grooved electrodes, the best helix angles are 30°, 35°, 40°, 45°which is in agreement with the findings of Burek et al 17 for studies on the effect of helix angle in chip removal during milling. And for the double-helical tools, the best helix angles for debris removal are 30°, 35°, 40°, 45°, 50°, 55°.…”

Section: Results Of Simulationsupporting

confidence: 90%

Effect of micro double helical grooved tools on performance of electric discharge drilling of Ti-6Al-4V

Krupa

Samuel

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Machining of complex features and holes on superalloys is a topic of both industrial and academic interest. Though the demand for high aspect ratio holes on Ti-6Al-4V is high in aerospace, biomedical and chemical industries, machining the same is very challenging due to the low thermal conductivity and debris accumulation in the machining zone. The present-day methods of hole drilling by unconventional methods like Electric Discharge Machining (EDM) make use of electrodes with poor flushing capabilities. Hence the motivation of the present work is to develop a method to modify the geometry of Electric Discharge Drilling (EDD) tools in order to enhance debris removal. For the first time an attempt has been made to machine micro double-helical grooves on EDD tools in a single pass. Solid, single-helical and double-helical electrodes are developed and through-holes are drilled on a Ti-6Al-4V workpiece. A comparative analysis of the performance of these three types of tools with respect to the machining time, electrode wear rate and hole quality is carried out. From Computational Fluid Dynamics (CFD) simulations it is seen that the double-helical grooved tool is superior in debris removal. The best values of the machining time of 183.33 s, overcut of 2.19 mm, hole taper angle of 7.93° and area of recast layer of 6.66 mm2 are obtained on the holes machined using double-helical electrodes. The mentioned tool has the potential to overcome the problem of debris removal in high aspect ratio hole drilling and surpass the present-day electric discharge drilling tools.

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Section: Results Of Simulationsupporting

confidence: 90%

Effect of micro double helical grooved tools on performance of electric discharge drilling of Ti-6Al-4V

Krupa

Samuel

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…In most cases, the higher values of the F y component, for both variables, were obtained by using the tool with the helix angle λ s = 20˚. Milling with a tool with angle λ s = 45° led to lower values of the F y component [32].…”

Section: Resultsmentioning

confidence: 96%

“…This can be explained by the effects of the helix angle on the speed with which chips are evacuated from the cutting zone and the direction in which they flow. For low values of the angle λ s chips flow axially, whereas when λ s is higher the direction of chip flow is radial [32]. The considered cutting parameters and tool geometry affected the material height differences to varying degrees.…”

Section: Resultsmentioning

confidence: 99%

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Effect of Machining Settings and Tool Geometry on Surface Quality After Machining of Al/CFRP Sandwich Structures

Doluk¹,

Rudawska²

2022

Adv. Sci. Technol. Res. J.

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The paper describes the effect of cutting parameters and tool geometry on the surface quality after machining of an Al/ CFRP (aluminium alloy/ Carbon Fibre Reinforced Plastics) sandwich structure. A two-layer sandwich structure made of an EN AW 2024 aluminium alloy and Carbon Fibre Reinforced Plastics (CFRP) was examined. The experiment used the process of peripheral milling. The experiment investigated the effects of cutting speed (v c ), feed per blade (f z ) and helix angle (λ s ) on surface quality as defined by differences in the height of materials. It was also analysed how the machining conditions described above affected the values of cutting force components. In the experimental stage of the study, uncoated, double-bit carbide mill cutters with working diameter D c = 12 mm and a variable helix angle (λ s = 20°, λ s = 35°, λ s = 45°) were used. The results have shown that cutting parameters and tool geometry do affect the surface quality and cutting forces after milling of the sandwich structure. The lowest material height difference was achieved when machining with the helix angle λ s = 45°, cutting speed v c = 300 m/min and feed per blade f z = 0.08 mm/blade. The highest material height difference occurred after machining under the following conditions: v c = 300 m/min, f z = 0.08 mm/min, λ s = 20°. The minimum cutting force value was obtained for cutting parameters: v c = 80 m/min, f z = 0.08 mm/blade during milling with the helix angle λ s = 45°. The maximum cutting force was recorded during machining with the helix angle λ s = 20˚, cutting speed v c = 400 m/min and feed per blade f z = 0.08 mm/blade.

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“…In addition, the helix angle λ s = 35° improves the chip evacuation process [ 28 ]. This is also important during CFRP machining.…”

Section: Methodsmentioning

confidence: 99%

Milling of an Al/CFRP Sandwich Construction with Non-Coated and TiAlN-Coated Tools

et al. 2020

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In this study, the effect of cutting parameters on the quality of an Al/CFRP sandwich structure (aluminium alloy–carbon fibre reinforced polymer) after milling with uncoated and TiAlN-coated tools was examined. The results of the cutting force were also investigated. The research was conducted in a VMC 800 HS vertical machining centre with a variable cutting speed and feed. The milling process was carried out using a non-coated, two-blade carbide milling cutter with a 35° helix angle and an analogous tool with a TiAlN coating. The surface quality was characterised in terms of the height deviation, which is one of the shape deviations after machining hybrid materials. The research showed that the maximum (77.60 µm) and minimum (1.78 µm) values of the height deviations were obtained using the tool with a TiAlN coating. It was found that the tested factors had significant effects on the height deviation, where the feed had the greatest influence and the cutting speed had the lowest influence on the surface quality. The tested factors were not statistically significant in terms of the cutting force.

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The effect of the cutting edge helix angle of the cutter on the process of chips removing from the cutting zone

Cited by 5 publications

References 4 publications

Effect of micro double helical grooved tools on performance of electric discharge drilling of Ti-6Al-4V

Effect of micro double helical grooved tools on performance of electric discharge drilling of Ti-6Al-4V

Effect of Machining Settings and Tool Geometry on Surface Quality After Machining of Al/CFRP Sandwich Structures

Milling of an Al/CFRP Sandwich Construction with Non-Coated and TiAlN-Coated Tools

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