Face Milling Process Research Articles

Optimization of cutting parameters using response surface methodology (RSM) in milling Inconel 718 superalloy using Borax-added nanofluid in (MQL) system

PurposeThe need for materials with superior mechanical and physical properties has recently increased. Inconel 718, one of these superalloys, is frequently used in the aviation and space industry. However, during Inconel 718 superalloy machining, cutting tools and cutting fluid were excessively consumed. This study aims to investigate using an innovative and environmentally friendly cutting fluid in milling the Inconel 718 superalloy.Design/methodology/approachIn this study, a Borax- (BX-)added cutting nanofluid was prepared and used for the first time as a coolant in the minimum quantity lubrication (MQL) system of Inconel 718’s face milling process. Response surface methodology (RSM) was used to determine the effect of the BX element on cutting performance. Face milling operations were carried out by adding BX elements at 1.5% and 3% at two different rates.FindingsAs the BX additive ratio in the cutting fluid used in the MQL system increased, the cutting force values decreased. The lowest cutting force value was measured in the tests with cutting fluid containing 1.5% BX. In addition, a smoother surface was obtained by adding 1.5% BX to the cutting fluid. Furthermore, cutting tool life increased by 20% compared to 0% by 3% BX nanofluid concentration.Originality/valueThe study is innovative regarding the material processed, the cutting fluid used and the method used for the aerospace industry.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0191/

Modeling of milling forces in facing process of aluminum alloy AL7075 using the square inserts

Cutting forces play very important in designing the tool machine, cutting tool, and in optimization of machining processes. Modeling and prediction of cutting forces by theoretical methods are quite difficult, so, this study was focused on modeling the cutting force in face milling process using combination of theoretical and experimental methods. This study was performed to model the milling forces (MFs) and determine the milling force coefficients (MFCs) in the face milling process of aluminum alloy Al7075 using square inserts. From theoretical and experimental methods, the relationship of average milling forces (AMFs) and feed per flute (ft) were determined as the linear regression. Using experimental data, the linear regressions of AMFs and feed per flute were determined with high values of determination coefficients (larger than 95 %). MFCs were determined including shear and edge MFCs (tangential shear MFC (Ktc) of 538.127 N/mm2, radial shear MFC (Krc) of 185.967 N/mm2, axial shear MFC (Kac) of -691.297 N/mm2, tangential edge MFC (Kte) of 11.253 N/mm, radial edge MFC (Kre) of 6.991 N/mm, and axial edge MFC (Kae) of –32.971 N/mm. The MF models were successfully verified by comparing the measured and predicted MFs in face milling process of Al7075. The tendency and shape of predicted MFs were quite close to the measured ones. The differences between the predicted and the measured MFs can be due to the several reasons such as the influence of vibrations, the influence of cutting heat, etc., and these are also the limitations of this study. The modeling and prediction methods of this study can be used to model and predict the cutting forces in face milling of other milling types and other pairs of cutting tool and workpiece material as well

Surface integrity and modification of SA508Gr.3Cl.2 RPV steel induced by high-speed face milling process

Surface integrity and modification of SA508Gr.3Cl.2 RPV steel induced by high-speed face milling process

Corrosion Behaviour of Stainless Steel 316L in Chloride Environment After Dry Machining by Face Milling at Various Spindle Speed

This study attempts to investigate the impact of spindle speed on the corrosion characteristics of 316L stainless steel during the face milling process in dry condition. The machining parameters, such as spindle speed, have an impact on the surface properties of the material after the processes. It is essential to devote significant attention that these parameters can still affect the surface condition of 316L stainless steel, which may then affect its corrosion properties. This research aimed to examine the corrosion characteristics of 316L stainless steel subsequent to the face milling process using the potentiodynamic polarization technique in a chloride-containing environment. The face milling technique use a 6 mm carbide cutter tool, with spindle speed variations of 1800 rpm, 1600 rpm, and 1400 rpm. The feed rate is maintained in constant rate, which is 0.002 mm/rev. The findings of the corrosion rate test indicate that variations in spindle speed lead to fluctuations in the corrosion rate value. There finding shows an inverse relationship between the value of spindle speed and the corrosion rate, wherein an increase in spindle speed corresponds to a decrease in the corrosion rate.

ANALYSIS OF CUTTING FLUID ON MASS LOSS OF CARBIDE INSERT IN THE MILLING PROCESS

The Machining process is manufacturing in the world industry that is widely used. The coolant in the machining process functions to lower the temperature and lubricate and clean the gram in the cutting process. The application of coolant in the cutting process is to maintain the quality of the workpiece during the cutting process and also serves to improve tool life so that the tool does not wear out easily. This study aims to determine the effect of a chemical-based coolant based on dromus oil and vegetable CPO on tool wear in the face milling process and to determine whether or not the liquid is effective in reducing and slowing down tool wear. In this research, the face milling process used a grey cast iron specimen as the workpiece specimen used and also used a carbide insert chisel cutting tool with the TPKN 22 VC2 type. The research was carried out by varying the engine speed and also the coolant variation, the engine speed variations used were 80, 360 and 720 Rpm. In the process of administering coolant using the method, it is sprayed directly onto the workpiece area which is cut continuously, in the milling process with a response variable that can be in the form of data or tool wear values that have been observed and tested using a microscope test tool, using the weight (mass) method to see the wear value. This research aims to see how effective the use of vegetable- based coolant (CPO) during experiments as a coolant in the machining process aims to ensure that the final value of tool insert wear must be smaller with (CPO) compared to chemical coolant (dromus).

PENGARUH PENGGUNAAN MINYAK JAGUNG UNTUK CUTTING FLUID PADA PROSES FACE MILLING TERHADAP KEKASARAN PERMUKAAN PERMUKAAN DAN LAJU KOROSI BAJA KARBON

The corrosive coastal environment will result in a high corrosion rate for any equipment installed there. This is due to the constant exposure to saltwater, high humidity levels, and strong winds. Therefore, it is crucial to use corrosion-resistant materials and regularly maintain the equipment to ensure its longevity in such an environment. One method to reduce the rate of corrosion is to pay close attention to the manufacturing parameters of these components, one of which is the face milling process. The aim of this study is investigating the effect of face milling process with different dept of cut using minimum quantity lubrication method with corn oil as a renewable vegetable cutting fluid. In this study AISI 316L stainless steel was face milled using HAAS VF-2 CNC machine. The depth of cut is varied between 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, and 0.6 mm. The results demonstrated that the greater the depth of cut, the greater the surface roughness value that will be generated. It is resulting in increment in the corrosion rate value.

The clamping selection method to reduce vibration of large-size workpiece during the face milling process

The clamping selection method to reduce vibration of large-size workpiece during the face milling process

A high efficiency 3D surface topography model for face milling processes

Predicting the 3D surface topography in milling is the basis of analyzing its surface contact properties. However, most studies have been devoted to improving the accuracy of models and ignoring the efficiency of models, which has resulted in predicting the surface topography of large-size face milling becoming a time-consuming task. In this paper, a high efficiency 3D surface topography prediction model was proposed for face milling processes. The high efficiency of the proposed model was demonstrated by reducing the data volume and optimizing algorithms. First, a traditional 3D surface topography model was developed. Then, a high efficient 3D surface topography model was proposed based on the optimization of the data volume and algorithms. Next, the validity of the proposed model was verified by face milling experiments. Finally, compared with traditional models and other models, the proposed model had the highest computational efficiency. The proposed model provides a method for surface topography analysis of large-size face milling and an insight for optimizing other models.

Optimization of Machining Variables of Inconel 800 Alloy in CNC Face Milling Using TiAlN and TiAlN-TiN Coated Inserts

This research work is based on the machinability of an Inconel 800 alloy using TiAlN-coating and TiAlN-TiN-coating tools. In the CNC VMC Face milling process feed, depth of cut (DoC), and cutting speed consider input variables and surface roughness, Tool wear is measured for all machining conditions. To enhance the machining conditions a Taguchi L9 Design of Experiment was created. ANOVA analysis was used to identify the important variables influencing Flank wear (tool wear) and surface roughness. The signal-to-noise ratio for the ideal cutting combination was identified by evaluating the optimum surface roughness and tool wear. for the effect of coating, a comparison was done between the findings obtained using both TiAlN-coated and TiAlN-TiN tungsten carbide-coated tools. The best optimum surface roughness and tool wear of the experiment conducted under machining with TiAlN-TiN coated carbide tool resulted in .3433 µm and 128 µm respectively.

A novel tool path planning and feedrate scheduling algorithm for point to point linear and circular motions of CNC-milling machines

The manufacturing process on CNC machines is directed by the Numerical Control (NC) files which include the main tool paths as a combination of numerous instructions such as lines and arcs specified by the G01 and G02/G03 commands. In the literature, the lines and arcs generally are converted to a parametric curve based on the global tool path smoothing or local corner smoothing algorithms. However, the smoothing methods cause the deflection from the tool path in NC-File. In cases where the deflection from the main tool path is not acceptable, point-to-point motion is necessary instead of the smooth trajectory. This study presents a novel trajectory planning and feedrate scheduling algorithm for point-to-point control of linear and circular paths in the NC-File. The proposed method prevents the feedrate fluctuations at the junction points and generates the tool path without deflection from the NC-File. Also, the feedrate scheduling algorithm decrease the operating time of the machine significantly compared to traditional method of point-to-point motion. This study is verified on an industrial 3-Axis CNC-Milling machine by the operating of the roughing milling, drilling, slotting, and face milling process. The measurements of final product and real-time trajectory tracking results show that the proposed method is effective in industrial applications of CNC-Milling machines in which point-to-point motion is necessary.

Modelling of the Face-Milling Process by Toroidal Cutter

When face milling using a toroidal cutter, with a change in the depth of the cut, the entering angle varies as well. An experimental test of the influence of cutting parameters, such as the depth of the cut and the feed per tooth on the cutting force components and surface roughness parameters, was conducted. The experimental test was carried out using a DMU 100 monoBLOCK CNC machine with registration of cutting force components and surface roughness parameters Ra, Rz, and RSm. FEM analysis of the face-milling process was also carried out and compared with the experimental results. The average deviation of the FEM values for cutting force components does not exceed 12%. Experimental models were established for each force component. It was shown that the depth of the cut has the strongest influence on each force component. The feed per tooth has a little impact on the cutting force. The obtained model of the feed force component is the most complex, and the model of the Fa component is only linear. The influence of the ap parameter on the surface roughness parameters is nonlinear and nonmonotonic. In the range of approx. ap = 2 mm, there is a maximum surface roughness.

Effect of increased mechanical strength on the machinability of graphite cast irons in face milling

Due to the low cost and high vibration damping capacity, gray cast irons are commonly used in machine tool bases, in addition to applications with noise restrictions, such as engine blocks, housings, and brakes. The matrix’s graphite, sulfides, and ferrite/pearlite ratio are some of the most important parameters governing the machinability of the gray cast irons. This work aims to evaluate the machinability of high-resistance gray cast irons of the FC 300 grade, in two versions, with the addition of molybdenum (FC 300 (Mo)) and with refined graphite and addition of molybdenum (FC 300 (Mo+RG)), for use in cylinder heads and engines blocks, compared to materials that have been used for this purpose, gray cast iron FC 250 and the compacted graphite cast iron FV 450. The materials were characterized according to the cementite interlayer spacing and microhardness of the perlite matrix, the number of eutectic cells, and the distribution of manganese sulfide inclusions, with those characterizations being correlated with the machinability results. The face milling process was chosen for the tests with uncoated cemented carbide tools without cutting fluids; the cutting speed and feed rate varied in addition to the type of cast iron. Analysis of tool life, wear mechanisms, and machined surfaces’ quality (Ra roughness parameter) were the output variables considered. Using harder materials such as FC 300 (Mo) or FC 300 (Mo+RG) for the engine would bring benefits such as increased durability, reduced weight, and improved efficiency, but it has a cost in machining. These harder materials have a shorter tool life compared to the commonly used gray cast iron FC 250, but the difference in performance is less pronounced under more extreme cutting conditions, such as high cutting speed and feed rate. When analyzing the surface roughness, FC 250 produced a smoother surface at low cutting speeds but performed worse than FC 300 (Mo) and FC 300 (Mo+RG) at higher cutting speeds.

Investigation of cutting force components and surface roughness in face milling with different cutting ratios

During the face milling process, the choice of technological parameters plays an important role. The two most important parameters are the feed and the depth of cut, the ratio of which is also called the cutting ratio. The main topic of the paper is to examine how different values of the chip ratio affect the components of the cutting force and the roughness of the machined surface. It is also shown how important it is to know the exact geometry of the cutting insert, as well as - in the case of cutting with multiple inserts - the knowledge of the run-out between the individual inserts. Based on the performed investigations, it was determined that the use of a chip ratio close to 1 is not recommended either in terms of cutting force components or surface roughness.

Effect of Machining Directions on Surface Integrity of AISI 1018 Steel in a Face Milling Process

This study analyses the effect of machining directions on surface integrity of AISI 1018 steel by performing a face milling operation using the zag toolpath strategy; undertaking a detailed surface roughness check of the machined surface in the cutting and feed directions; studying the microstructure of the as-received workpiece and subsurface of the machined part in the cutting and feed directions in 2% Nital etching; and comparing the grain size before and after the cutting process. Results show that surface roughness values were minimal when measurements were conducted at the middle of the machined surface. Also, surface roughness values were higher in the feed direction than in the cutting direction by 13% due to the presence of feed marks which were clearly visible on the machined surface. The grains at the top machined surface were deformed, elongated, and oriented in the cutting direction as a result of plastic deformations experienced in the machining process, while the grains were also elongated and disoriented in the feed direction. Surface damages caused by the cutting tool’s engagement of the workpiece were clearly seen at the side of the machined surface’s edge. The average grain size value before machining was higher than the average grain size value after machining by 27%, attributed to the plastic deformation of the grain structure as a result of machining. This study has provided an in depth knowledge and understanding of the influence of plastic deformation due to machining on surface roughness and microstructure of the machined part.

Influence of the Milling Conditions of Aluminium Alloy 2017A on the Surface Roughness.

The article presents the results and process analysis of the face milling of aluminium alloy 2017A with the CoroMill 490 tool on an AVIA VMC 800 vertical milling centre. The study analysed the effects of the cutting speed, the feed rate, the actual number of teeth involved in the process, the minimum thickness of the cut layer (hmin), and the relative displacement in the tool-workpiece system D(ξ) on the surface roughness parameter Ra. To measure relative displacement, an original bench was used with an XL-80 laser interferometer. The analysis of relative displacement and surface roughness allowed these factors to be correlated with each other. The purpose of this article is to determine the stable operating ranges of the CoroMill 490-050Q22-08M milling head with respect to the value of the generated relative displacement w during the face-milling process and to determine its influence on surface roughness. The research methodology presented in this paper and the cutting tests carried out allowed the determination of the optimum operating parameters of the CoroMill 490-050Q22-08M tool during the face milling of aluminium alloy 2017A, which are vc 300 m/m and fz—0.14 mm/tooth. Working with the defined cutting parameters allows all the cutting inserts in the tool body to be involved in shaping the geometrical structure of the surface, while maintaining a low vibration level D(ξ) > 1 µm, a low value of the parameter hmin > 1.5 µm, and the desired value of the parameter Ra > 0.2 µm

Sistem za praćenje stanja alata u više tačaka - uporedna studija

In the metal removal process, the condition of the tool plays a vital role to achieve maximum productivity. Hence, monitoring the tool condition becomes inevitable. The multipoint cutting tool used in the face milling process is taken up for the study. Cutting inserts made up of carbide with different conditions such as fault-free tool (G), flank wear (FW), wear on rake face (C) and tool with broken tip (B) are considered. During machining of mild steel, vibration signals are acquired for different conditions of the tool using a tri-axial accelerometer, and statistical features are extracted. Then, the significant features are selected using the decision tree algorithm. Support Vector Machine(SVM) algorithm is applied to classify the conditions of the tool. The results are compared with the performance of the K-Star algorithm. The classification accuracy obtained is encouraging hence, the study is recommended for real-time application.

Analysis of tool wear in face hobbing plunging manufacturing processes

For soft machining of bevel gears, multi-part tool systems consisting of a cutter head and stick blades are commonly used. In the past, experimental investigations regarding the tool wear in bevel gear milling have been carried out, aiming to optimize the process design and thus the process economic efficiency. However, the existing investigations refer only to face milling processes. In this paper, a tool wear study for an industrial application of the face hobbing plunging process is presented. Additionally an analogy trial of the process is designed. Based on the findings, it is concluded that the designed analogy trial is suitable for analyzing the tool wear development for face hobbing plunging processes.

Effect of feed rate and depth of cut on face milling process on surface roughness of Al-Mg alloy using CNC milling machine 3 axis

The purpose of this study was to determine the effect of feed rate and depth of cut on the surface roughness of Al-Mg aluminum using a DIY CNC Milling Machine and Krisbow Universal Milling Machine as a comparison. The open-loop control system is a control system used in the design of DIY CNC Milling machines. A PC with Mach3 software is used as a PC Based Direct Digital Controller to control the system. In this study, the feed rate variation 24 mm/minute and 42 mm/minute and depth of cut 0.25 mm, 0.5 mm, and 0.75 mm were used. After the face milling process, the surface roughness test was carried out using the Mitoyo Surface Roughness Tester to determine the level of surface roughness of the machining results the DIY Milling Machine and Krisbow Universal Milling Machine as a comparison. The results showed that as the feed rate and depth of cut increased, the surface roughness values of both tools increased.

A method of predicting the best conditions for large-size workpiece clamping to reduce vibration in the face milling process

The paper presents an innovative method of solving the problem of vibration suppression during milling of large-size details. It consists in searching for the best conditions for clamping the workpiece based on a rapid modal identification of the dominant natural frequencies only and requires repetitive changes in the tightening torque of the clamping screws. Then, by estimating the minimum work of the cutting forces acting in the direction of the width of the cutting layer, it is possible to predict the best fixing of the workpiece. Application of the method does not require the creation and identification of a computational model of the process or preliminary numerical simulations. The effectiveness of this method was confirmed by the evaluation of the Root Mean Square (RMS) of the vibration level in the time domain observed during the actual face milling process. The worst results were obtained for the configuration of supports tightened with a torque of 90–110 Nm, and the best—with a torque of 50 Nm.

A development method of cutting force coefficients in face milling process using parallelogram insert

This paper presents a modeling method of cutting force and a combination approach of theory and experimental methods in the determination of cutting force coefficients in the face milling process using a parallelogram insert. By the theoretical method, the cutting forces were modeled by a mathematical function of cutting cutter geometry (Cutter diameter, the number of inserts, the insert nose radius, insert cutting edge helix angle, etc.), cutting conditions (depth of cut, feed per flute, spindle speed, etc.), and cutting force coefficients (shear force coefficients, edge force coefficients). By the theoretical method, the average cutting forces in three directions (feed – x, normal – y, and axial – z) were modeled as the linear functions of feed per flute. By the experimental method, the average cutting forces in these three directions were also regressed as the linear functions of feed per flute with quite large determination coefficients (R2 were larger than 92 %). Then, the relationship of average cutting forces and feed per flute was used to determine all six cutting force coefficient components. The validation experiments were performed to verify the linear function of average cutting forces, to determine the cutting force coefficients, and to verify the cutting force models in the face milling process using a cutter with one parallelogram insert. The cutting force models were successfully verified by comparison of the shape and the values of predicted cutting forces and measured cutting forces. These proposed methods and models can be applied to determine the cutting force coefficients and predict the cutting force in the face milling process using a parallelogram insert and can be extended with other cutting types or other insert types