Abstract
The machining of free form surfaces is one of the most challenging problems in the field of metal cutting technology. The produced part and machining process should satisfy the working, accuracy, and financial requirements. The accuracy can describe dimensional, geometrical, and surface roughness parameters. In the current article, three of them are investigated in the case of the ball-end milling of a convex and concave cylindrical surface form 42CrMo4 steel alloy. The effect of the tool path direction is investigated and the other cutting parameters are constant. The surface roughness and the geometric error are measured by contact methods. Based on the results, the surface roughness, dimensional error, and the geometrical error mean different aspects of the accuracy, but they are not independent from each other. The investigated input parameters have a similar effect on them. The regression analyses result a very good liner regression for geometric errors and shows the importance of surface roughness.
Highlights
The machining of free form surfaces is a focused problem in the mould and die industry and in power plant turbines
The investigation of free form surface machining has many different aspects, but we focus on the process planning and the application of CAM systems
Thequality qualityofof ofa amachine a machine machine part can be characterized by several properties and parameters, and
Summary
The machining of free form surfaces is a focused problem in the mould and die industry and in power plant turbines. The working requirements, the productivity, the required accuracy and the measuring possibilities must be considered. Products such as moulds and dies often have complex shapes and very accurate dimensions. These elements are generally made of alloys commonly referred to as hard-to-cut materials. Several types of such materials can be distinguished, depending on their features. The most known types are materials with low thermal conductivity, such as super alloys and titanium, a ductile material such as pure nickel, a material with high hardness and brittleness, such as ceramics [1,2,3]. Materials with unique metallurgical properties—such as titanium, tool steels, stainless steels, hardened steels and other super alloys—were developed to meet the demands of extreme applications
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