The Study of Tool Wear Performance on Pocket Milling Strategy

Abstract

The increasing productivity demand in machining industry has lead for fast material removal machining technique of pocket milling using different tool path strategies. This project aims to study about the effect of different tool path strategies on tool wear when machining aluminium alloy 7076. Five milling strategies were evaluated outward helical, inward helical, back and forth, offset on part one-way and offset on part zigzag. CATIA V5R19 was used to setup milling path and the machining experiments were carried out on a HAAS’ 3 axis CNC milling machine. The machining was held under wet condition with 2500 rpm cutting speed, 800 mm/min feed rate, 2 mm radial depth of cut and 2 mm axial depth of cut. The results showed that the best tool path strategies are inward helical and offset on part one-way, while the worst tool path strategy is outward helical. Failure to evacuate chip during pocket milling is the main reason to cause rapid tool wear due to temperature rise and higher contact time and area of cutting tool with the chip. Results from this experiment help to guide the machinist to perform pocket milling effectively.

Application of response surface methodology (RSM) to the prediction of the service life of cutters used in milling super-alloy Waspaloy

“…In addition, the wearing increases when the feed rate and depth of cut are fixed, and the machining speed increases from Vc = 30 m/min to Vc = 43 m/min. …………………………………………………………………………………………………………………………… (11) When the response surface is moving away from the best condition position, there is only little curvature in the system, and the first order model is appropriate. The objective is to move to an approximate value as close to the best-fit value as possible.…”

“…For the machining of nickel-based materials, hardening precipitation and diffusion affinity lead to premature wearing of cutters. The better the cutters are in heat resistance, the greater the n value is (Chen and Ho, 2019; Hadzley et al, 2015;Ginta et al, 2009;Muñoz-Sánchez et al, 2011). The tool wear is closely related to material removal rate which is proportional to feed rate, machining depth and width.…”

Lifespan of super-alloy Waspaloy cutting tools

“…The abrasion of cutting tools will direct influence processing efficiency and precision. So it is considerably important to predict the life of cutting tools accurately [1, 2, 3]. Response Surface Methodology (RSM) can be applied to WC-Co cutting tool without coating.…”