The influence of tool flank wear on residual stresses induced by milling aluminum alloy

Abstract.A wear of cutting tools during machining process is unavoidable due to the presence of frictional forces during removing process of unwanted material of workpiece. It is unavoidable but can be controlled at slower rate if the cutting speed is fixed at certain point in order to achieve optimum cutting conditions. The wear of cutting tools is closely related with the thermal deformations that occurred between the frictional contact point of cutting edge of cutting tool and workpiece. This research paper is focused on determinations of relationship among cutting temperature, cutting speed, cutting forces and radial depth of cutting parameters. The cutting temperature is determined by using the Indium Arsenide (InAs) and Indium Antimonide (InSb) photocells to measure infrared radiation that are emitted from cutting tools and cutting forces is determined by using dynamometer. The high speed machining process is done by end milling the outer surface of carbon steel. The signal from the photocell is digitally visualized in the digital oscilloscope. Based on the results, the cutting temperature increased as the radial depth and cutting speed increased. The cutting forces increased when radial depth increased but decreased when cutting speed is increased. The setup for calibration and discussion of the experiment will be explained in this paper.

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“…Tang et al [7] have found the correlation between wear and cutting forces. As the cutting forces increases, the flank wear will also increase.…”

Section: Introductionmentioning

confidence: 97%

Study of Cutting Edge Temperature and Cutting Force of End Mill Tool in High Speed Machining

et al. 2017

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“…The temperature in the machining not only affects the tool wear, but also directly influences the residual stresses [12]. It is well known that machining processes create residual stresses on the surface of machined components [1]. Residual stresses can be defined as tensile and compressions that exist in the material following a manufacturing process.…”

Section: Introductionmentioning

confidence: 99%

“…Residual stresses can be defined as tensile and compressions that exist in the material following a manufacturing process. Residual stresses induced by material removal have a major influence on the life time of machined pieces especially in its corrosion resistance and fatigue life [1][2][3][4][5][6][7][8][9][10][11][12][13][14]. Residual stresses can cause part distortion especially in the case of large components such as structural parts in industry, [15.17].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigations to evaluate the effects of cutting parameters on cutting temperature and residual stresses during milling process of the AISI 1045

Abdelkrim

Brabie

Belloufi

et al. 2017

IOP Conf. Ser.: Mater. Sci. Eng.

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Abstract. Today major metal cutting companies in industrial countries, looking to gain time and reduce manufacturing costs while respecting the environment. There are many phenomena which affect the quality and production costs of the product, including cutting efforts, cutting temperature, residual stresses, etc. A better understanding of these phenomena will reduce production costs and maximize productivity. The aim of this work is to analyze the effect of machining conditions (cutting speed, feed speed and cutting depth) on cutting temperature and residual stresses, during the milling operations using the response surface method. A good accuracy between predicted and measured values of the cutting temperature was found, the cutting speed and the depth of cut are parameters whose effect is most sensitive to the residual stresses and the cutting temperature.However, little influence has been registered in the case of an increase of the feed rate. The percentage of error is 4.57%, indicating that the numerical approach can accurately predict the cutting temperature of the AISI 1045.

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“…Machining operations would generate geometric distortions and a high level of surface residual stresses, which has been studied extensively in terms of machining techniques (El-Khabeery and Fattouh, 1989;Rao and Shin, 2001; Ee et al, 2005;Ulutan et al, 2007;Denkena et al, 2008;Tang et al, 2009) but has not yet been considered in springback predictions for CAF. The machined plate normally contains different thickness at different sections.…”

Section: Introductionmentioning

confidence: 99%

“…These residual stress profiles can be affected by the individual influence of, or interactions amongst, machining parameters (El-Khabeery and Fattouh, 1989), cutting temperature (Ulutan et al, 2007), boundary and loading conditions (Denkena et al, 2008), as well as the cutting tool's material (Rao and Shin, 2001), geometry (Ee et al, 2005) and even its degree of wear (Tang et al, 2009 …”

Section: Introductionmentioning

confidence: 99%

Influences of residual stresses and initial distortion on springback prediction of 7B04-T651 aluminium plates in creep-age forming

Lam

Shi

Lin

et al. 2015

International Journal of Mechanical Sciences

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Abstract. Springback behaviour of surface-machined 7B04-T651 aluminium plates of 3 to 8 mm thicknesses, creep-age formed under a single curvature bending radius of 1200 mm, has been experimentally investigated. The surface residual stress levels of the plates have been measured and the typical residual stress distribution and values in 7000-series aluminium alloys have been reviewed and analysed. Finite element models have been developed to simulate creep-age forming (CAF) processes and predict the amount of springback in the physical CAF test. Machining-induced residual stresses and distortion have been considered in the finite element models. This paper presents a first attempt to study the effect of machining-induced residual stresses on the errors of springback prediction in CAF of 7000-series aluminium alloy panel components. It has been found that the effect of machininginduced residual stresses on the accuracy of springback prediction is related to the initial loading stress levels in CAF. In addition, when the initial distortion conforms to the loading curvature, an opposing effect on the material's deformation is observed. Creep-ageing material constant related to effective creep strain rate.1 Creep-ageing material constant related to rate of age hardening.2 Creep-ageing material constant related to the depletion of solute into precipitate.3 Creep-ageing material constant related to rate of precipitate growth.4 Creep-ageing material constant controlling the effect of dislocation density (or creep) on precipitate nucleation and growth.5 Creep-ageing material constant related to rate of dislocation density.Creep-ageing material constant related to rate of dislocation hardening.Bending radius of forming tool.̅ , ̅ Normalised precipitate size and its rate term respectively. ̅ 0 Initial value for normalised precipitate size.Radius of revolvement of workheads of the flexible form tool.Creep-ageing time.1 , 2 , 3 , 4 Time of loading, heating, cooling and unloading respectively. Artificial ageing time.Solution heat treatment time., , Translational degrees of freedom in Cartesian coordinates., , Rotational degrees of freedom in Cartesian coordinates.Poisson's ratio., , Cartesian coordinates., positions of the lower and upper splines respectively.

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The influence of tool flank wear on residual stresses induced by milling aluminum alloy

Cited by 99 publications

References 21 publications

Study of Cutting Edge Temperature and Cutting Force of End Mill Tool in High Speed Machining

Study of Cutting Edge Temperature and Cutting Force of End Mill Tool in High Speed Machining

Experimental Investigations to evaluate the effects of cutting parameters on cutting temperature and residual stresses during milling process of the AISI 1045

Influences of residual stresses and initial distortion on springback prediction of 7B04-T651 aluminium plates in creep-age forming

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