Abstract
Magnesium alloy has attracted more attentions due to its excellent mechanical properties. However, in process of dry cutting operation, many problems restrict its further development. In this article, the effect of cutting parameters on machinabilities of magnesium alloy is explored under dry milling condition. This research is an attempt to investigate the impact of cutting speed at multiple feed rates on cutting force and surface roughness, while a statistical analysis is adopted to determine the influential intensities accurately. The results showed that cutting force is affected by the positively constant intensity from feed rate and the increasingly negative intensity from cutting speed. In contrast, surface roughness is determined by the gradually increasing negative tendency from feed rate and the positive effect with constant intensity from cutting speed. Within the range of the experiments, feed rate is the leading contribution for cutting force while the cutting speed is the dominant factor for surface roughness according to the absolute intensity values. Meanwhile, the trends of influencing intensities between cutting force and surface roughness are opposite. Besides, it is also found that in milling magnesium alloy, chip morphology is highly sensitive to cutting speed while the chip quality mainly depends on feed rate.
Highlights
Dry milling is widely used in industrial manufacturing as a high performance cutting technology
Similar behaviors on cutting forces were observed in high-speed end milling of titanium alloy.[16]
In this study, the measured feed force and radial force as the dominant objectives are evaluated to research into the machinability of dry milling magnesium alloy
Summary
Dry milling is widely used in industrial manufacturing as a high performance cutting technology. To some extent, it has displaced turning and grinding process due to its high efficiency, low cost, and green manufacturing. Milling operation is a typical intermittent cutting process with multi-inserts. It has a distinct machining mechanism comparing with other cutting operations such as turning and grinding process, so that which would have diverse impacts on machinability of material. The various aspects of machinability for workpiece are mainly determined by cutting condition such as cutting parameters, coolant, and tool geometry. In the process of cutting, the machining properties of workpiece are generally evaluated according to two criteria, cutting force and surface roughness.
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