Abstract
This paper set out to investigate the effect of cutting speed vc and trochoidal step str modification on selected machinability parameters (the cutting force components and vibration). In addition, for a more detailed analysis, selected surface roughness parameters were investigated. The research was carried out for two grades of magnesium alloys—AZ91D and AZ31—and aimed to determine stable machining parameters and to investigate the dynamics of the milling process, i.e., the resulting change in the cutting force components and in vibration. The tests were performed for the specified range of cutting parameters: vc = 400–1200 m/min and str = 5–30%. The results demonstrate a significant effect of cutting data modification on the parameter under scrutiny—the increase in vc resulted in the reduction of the cutting force components and the displacement and level of vibration recorded in tests. Selected cutting parameters were modelled by means of Statistica Artificial Neural Networks (Radial Basis Function and Multilayered Perceptron), which, furthermore, confirmed the suitability of neural networks as a tool for prediction of the cutting force and vibration in milling of magnesium alloys.
Highlights
State-Of-The-ArtThe aircraft and automotive industries demand innovative modern components and parts of uncompromising quality, which would be unattainable without employing innovative materials and high-efficiency machiningemploying advanced tools and machining centres
There is a well-evidenced tendency showing that the cutting force components largely depend on the cutting process conditions, as concluded by Sivam et al [17], whose study involved the analysis of cutting forces and their response to selected input parameters recorded in ZE41 magnesium alloy dry face milling
AZ31 (MgAl3 Zn1 ) magnesium alloys—exhibiting high mechanical properties and very good corrosion resistance, which in turn earmark them for a number of different industrial applications
Summary
The aircraft and automotive industries demand innovative modern components and parts of uncompromising quality, which would be unattainable without employing innovative materials and high-efficiency machiningemploying advanced tools and machining centres. In order to enhance the stability and effectiveness of subtractive machining, a thorough analysis of real cutting forces and computer simulation are indispensable. The use of Mg alloys has a beneficial effect on an inherent component of machining—effective removal of machining allowances—which is often carried out by means of milling. Compared to the machinability of other materials, magnesium alloys are characteristically quick and effective to cut, which enables executing the process at large depths of cut and high feed
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
