Milling Insert Research Articles

Analysis on Thermal-Mechanics Coupling of Milling Insert Based on Principle of Cellular Automation

The thermal-mechanics coupling rule and analytic method of coupling based on principle of cellular automation (CA) have been put forward for the sake of solving coupling effect problem of multi-physics field on the milling insert during milling. The evolution rule of stress function was derived on milling insert according to thermal elasticity by analysis of thermal-mechanics coupling of milling insert based on principle of CA. The temperature change function of the milling insert was deduced in the event of fixed cutting parameter based on heat transfer theory. The local rule of CA on thermal-stress of milling insert was established. The influence factor and distribution regularities of thermal stress were obtained. Compared the numerical-value result of analysis on thermal-mechanics coupling based on principle of CA with analytic result of finite element method(FEM), the effectiveness of CA method was testified. A way of analysis with flexibility was provided for coupling problem of thermal stress field and mechanical stress field for milling insert. The theory basis of research was provided for optimum structural design of indexable milling inserts.

Study on Object Function of Milling Insert Impact Disrepair Based on Stress Field Analysis

This article takes the waved-edge milling insert (the rake face is curve plane) developed by Harbin University of Science and Technology as an example, as the goal of minimal impact disrepair, the optimization object function of the milling insert grooves is studied. Based on the force density function of the 3D complex groove milling insert, we have the finite element analysis on the stress fields of different cutting parameters, and have fuzzy synthetical judgement on the stress fields with fuzzy mathematic theory. We build the object function relation between the fuzzy synthetical judgement results and cutting parameters of the impact disrepair, so to have groove design optimization. All these studies provide the theoretic basis for the groove exploitation and the cutter disrepair which is the key problem in the automatization production and groove optimization.

Analysis and Study on Single Physics Field and Coupling Field of Cutting Tools for Machining Carbon Structural Steel

Based on the experiments on milling the carbon structural 45 steel with the flat rake milling insert and the waved-edge milling insert, the analysis and study on single physics field and coupling field are studied. On the basis of the milling force and milling temperature mathematical models, the force density function and heat density function of the waved-edge milling insert are built, the stress fields analysis and temperature fields analysis have been done. In order to discuss the distribution principle of equivalent stress and distortion under coupling condition, the coupling analysis on the stress field and temperature field is done. All these studies provide the theoretic and experimental basis for solving the cutter disrepair and groove optimization technology.

How mold inserts influence the replication of metallic microparts produced by electroplating into two-component templates

Multi-component injection molding combined with electroplating, the so-called MSG process, represents a promising process chain to replicate metallic microstructures. MSG is the German acronym of ‘Mehrkomponenten-Spritzgiesen und Galvanoformung’, in English ‘Multi-component Injection Molding and Electroplating’. The process is based on the highly accurate reproduction of surface details through injection molding to build a microstructure into a two-component template and electrodeposition of e.g. nickel into this cavity. This electroplated micropart is the replication of the former structure. To study the influence of the mold insert on the accuracy of the molded part and the produced microparts, a test specimen was fabricated and analyzed using a milled mold insert. On the mold insert, three microcoil parts, the components of a microgripper, were micromilled. The effect of the individual process steps on the surface quality and dimensional changes of the final microcoil will be presented. It will also be shown how the quality of the injection molding insert influences the dimensional accuracy of the produced microparts. Finally, potential process improvements will be outlined.

Study on Dynamic Equation of Cut-In Contact for the Waved-Edge Milling Insert with 3D Complex Groove

Cut-in disrepair of milling inserts are closely related to dynamic equation of cut-in contact. According to the problem of serious cut-in disrepair, dynamic equation of cut-in contact for the waved-edge milling insert with 3D complex groove is studied. Rake face function of 3D complex groove waved-edge milling inserts is founded. Rake face equation of 3D complex groove inserts is founded. Rake face motion equation of 3D complex groove inserts is deduced. Appearance equation of workpiece machining region is deduced. Contact line (LM) equation is deduced, which is the contact line between rake face and workpiece cut-in side surface when rake face moving. Intersection line (C1D1) equation is deduced, which is the intersection line of cutting surface and side surface of workpiece. All the production above are the theory foundation for further researching the relationship between the cut-in style and cut-in disrepair, cut-in style optimization, 3D complex groove insert optimization.

High bandwidth temperature measurement in interrupted cutting of difficult to machine materials

High-speed milling is used across industries from aerospace to electronics. Tool wear can be affected by cutting interruptions in milling that lower tool–chip interface temperatures but also cause thermal and stress cycling. Micro-thermal imaging was used to determine the temperature during interrupted cutting of titanium alloy Ti6Al4V and AISI 4140 steel for percentage of time-in-cut from 100% to 10%. TiAlN/TiN coated carbide milling inserts were used with cutting speeds up to 180 and 640 m min −1. This technique is the first to allow spatial mapping of thermal fluctuations on the tool which may be critical to determining causes for tool failure.

Study on Distributing Principle of Force Density Function for Complex Three-Dimension Groove Milling Insert

Based on the milling force testing experiments on machining the carbon structural 45 steel, the study on the distributing principle of force density function for complex three-dimension groove milling insert with the waved-edge milling insert (the curve rake plane) developed by Harbin University of Science and Technology is studied. On the basis of the milling force mathematical model, the force density function of the curve rake plane is built by the milling force experiments and tool-chip contact area experiments. Having quantitative calculation on the force density function and programming, the distributing model of force density function is shown with 3D figure, so to analyze its distributing principle. All these studies will provide a theoretic base for the stress field analysis and solving the cutter disrepair which is the key problem in the automatization production and groove optimization.

Experimental study on adhesive wear of milling insert with complex groove

This paper presents an experimental study on the adhesive wear of a milling insert with complex groove when milling 3Cr-1Mo-1/4V and 0Cr18Ni9 steels. Experimental measurements of milling temperature and milling force were performed. Then the adhesive behaviors and mechanisms between the steels and uncoated carbide were analyzed and discussed. It is found that the high temperature gradient, thermal stress, alternate compressive stress, and tensile stress in cut-in and cut-out, provide a situation for adhesion. Some suggestions for avoiding adhesive wear and the mechanism of adhesive wear of the insert are presented.

Thermal Imaging Experimental Research on Temperature Field for Milling Insert

During the process of interrupted cutting, milling insert suffers from periodic thermal shock. The bad temperature field caused by cutting heat is the direct reason for tool failure. In order to get more accurate temperature field distribution of milling insert, the experimental research on temperature field is carried on with the FLIR infrared thermal imager. This paper takes hard cutting material 3Cr1Mo1/4V as example. Through the contrast experiments, the temperature field distribution of tool-chip contact area is gained at the moment of milling insert going into or out from the workpiece, and also the difference of failure modes among different milling inserts is revealed. The experimental analysis results show that more accurate distribution of temperature field will be obtained when we apply the infrared thermal imager to observe temperature field during interrupted cutting process. Optimization design for groove of milling insert also can be based on those results.

Study on Simulation System of Cut-In Disrepair for the Milling Insert with 3D Complex Groove

The waved-edge milling insert is a kind of insert with 3D complex groove; its cut-in style and cut-in disrepair are different from the flat-groove insert. For researching the relationship between the cut-in style and the cut-in disrepair of the waved-edge milling insert, the cut-in simulation system of the waved-edge milling insert is developed, on the software of UG/Open API combined with VC++. By given different cut-in style parameters, the virtual cut-in process is founded and the proof is supplied for judging cut-in style and studying cut-in disrepair.

Cellular Automata Method for Reconstruction of Complex Groove of Milling Insert

This paper presents a self-organizing method for reconstruction of complex groove of milling insert. The local rule of Cellular Automata is proposed to design and optimize the groove of milling insert. The states of cells are modified according to the local rule applied. The state of the entire system is updated based on the state of the cell and its neighboring cell, and these cells’ states define the state of the entire domain, and the groove can be reconstructed. The reconstructed groove is tested by a FEM simulation. The simulation results show that the reconstructed groove has a satisfied performance on the stress field and temperature field.

Research on Temperature Field under Regular Gradient Heat Source of Milling Insert with Complex Groove Using Cellular Automata Algorithm

Lots of cutting heat is generated in milling process, and an unsteady temperature distribution is generated, which is the radical reason of impactive fracture and sticking-welding fracture of the tool. In this paper, the Cellular Automata model of regular gradient heat source on the rake face of milling insert is built using heat transfer theory and cutting principle to analyze the temperature field generated. The boundary condition of the insert is established and the unsteady temperature field of the insert is obtained using the Cellular Automata algorithm, which can be a basis for the direct reconstruction of the insert.

분말 혼합 공정으로 만들어진 은계 삽입금속의 특성

Ag계 분말 삽입금속을 볼 밀링법으로 제조하였다. 밀링공정의 변수들은 밀링시간을 제외하고는 일정하게 하였고 밀링 시간은 24, 48, 72시간들로 정하였다. 밀링에 의해 제조된 삽입금속들은 SEM관찰, DSC분석, 퍼짐성, 젖음성 시험을 통해 평가하였다. 삽입금속들의 브레이징부 특성은 상용금속에 비하여 우수하였다. 48시간 동안 밀링한 삽입금속이 퍼짐성과 젖음 특성이 가장 우수한 조건임을 나타냈다. 또한 브레이징부는 작은 양의 기공을 포함하고 있지만 안정적인 미세조직을 보였고 미세경도는 138VHN으로 나타났다. 【Powder type Ag system insert metals were manufactured by ball milling process. The variables of milling process were constant except the milling time. The milling times were selected for 24, 48 and 72 hours. The insert metals made by milling process were evaluated by performing scanning electron microscope, DSC(differential scanning calorimetry) analyses, spreading test and further in terms of wettability test. The selected insert metals that have the good characteristics compared to commercial insert metals were applied to make the brazed joints. The characterizations of those brazed joints were also conducted by microstructural observations. The results indicated that milling time of 48 hours for making powder type insert metals was the best condition showing the good spreadibility, low wetting angle. The brazed joints that applied the 48 hours milled insert metal were very sound condition indicating the stable microstructure in spite of containing small amount of porosity and the microhardness value of the joint was about 138VHN.】

Study on Impact Disrepair Mathematic Model and Groove Optimization of Cutting Tools for Machining Carbon Structural Steel

Based on the theoretic analysis and experiments on milling the carbon structural 45 steel with the flat rake milling insert and the waved-edge milling insert with complex 3D grooves which is developed by HarBin University of Science and Technology, we have studied on the impact disrepair mathematic model and groove optimization. On the basis of the milling force mathematic model and force density function of the waved-edge milling insert with complex 3D grooves the author built, we have the finite element analysis and blurry synthetical judgement of the 3D stress field, and forecast that the anti-impact disrepair capability of the waved-edge milling insert is choiceness. We find out the difference of the impact disrepair invalidation types between different grooves milling inserts by the experiments. Based on the plentiful and systemic impact disrepair experiments, as the emphasis in this paper, we build the impact disrepair life cumulating distribution function mathematic model by the mathematics statistic method and have contrast analysis of the impact disrepair average lives between the two types of milling inserts, and prove that the anti-impact disrepair capability of the waved-edge milling insert is choiceness. All these studies provide the theoretic and experimental basis for solving the cutter disrepair which is the key problem in the automatization production and groove optimization.

Research on Heating Density Function of Milling Insert with 3D Complex Groove

In order to figure out the temperature anywhere and anytime in the milling insert, based on the point heat source, and grounded on the experimental data, we established the mathematics model of heat density function and temperature field for milling insert with 3D complex groove under the irregular heat source, and has proved correctly to its special case with this mathematics model, thus established the theoretical foundation for groove optimizing and reconstruction of milling insert with 3D complex groove.

Study of Experiments on Cutting Difficult-to-Machine Materials with Ultrafine-Grained Waved-Edge Milling Insert

For the cutting of the difficult-to-machine materials, such as stainless steel and dead-hard steel, is always puzzling and restricting manufacturing, it is necessary to deeply study and search after new machining methods in respect of both theory and practice. This paper chose waved-edge milling inserts and flat-groove milling inserts of different materials to make cutting force contrast experiments on stainless steel ZG0Cr13Ni5Mo, chose ultrafine-grain inserts, YT14 inserts (local product) and CY250 inserts(foreign product) to make cutting life contrast experiments on dead-hard steel ZG35CrMo, then researched in theory the disrepair appearance, the BSE image and the granularity. The research results show that the integrated cutting capability of ultrafine grain waved-edge milling insert is excellent for difficult-to-machine materials.

Analysis of temperature field of milling insert with 3D complex groove using Cellular Automata

A numerical method for modelling the temperature field of milling insert with 3D complex groove is proposed based on the self-organising Cellular Automata. The self-organising local rule of Cellular Automata is derived to describe the heat transfer that affects temperature of milling insert using the finite difference theory. Consequently, a Cellular Automata model is built to predict the dynamic temperature field of the milling insert with 3D complex groove, which is also called wave-edge insert. Case studies are performed using sets of selected cutting conditions. Corresponding milling experiments and finite element analysis are also conducted to verify the simulation results of the Cellular Automata method. The comparison shows the validity and advantages of the proposed method.

Experiment, modeling, and analysis for temperature field of milling insert

This paper presents a theoretical and experimental study of the dynamic temperature field on a milling insert with complex groove. Experimental measurements of milling temperature using the thermocouple technique were performed. A mathematical model of the temperature field of the insert was established. A finite element model of the insert was built to simulate the temperature field. The boundary condition was determined by the experimental data and mathematical calculation, and then the temperature field of the milling insert was simulated through finite element analysis. The temperature distribution in a cut-in/cut-out cycle was obtained.

Research on Temperature Field of Milling Insert with 3D Complex Groove

Prediction of temperature field is a key technology to achieve the groove design and reconstruction of milling insert, predictive model of neural network is a new way to achieve the prediction of temperature field. According to the non-steady state characteristic of temperature field of milling insert, the paper puts forward a predictive model of temperature field of milling insert with 3D complex groove based on Levenberg-Marquardt algorithm of BP neural network, and it overcomes the disadvantage that traditional neural network is easy to fall into local minimum. The predictive results show that this predictive model can converge quickly and predict accurately.

Research on Heating Density Function and Temperature Field Mathematical Model for Milling Insert with 3D Complex Groove

Based on the milling temperature experiments and researches, we established the milling temperature mathematical model using dimension analytic method,and the heat density function and superficial heat density function of the flat milling insert and the waved-edge milling insert, whose rake face is wave curve plane and created by the authors using the diathermanous theory. We describe the mathematic model of the instantaneous temperature field by the theory of the finite moving planar sources of heat. At last, a program was done to calculate the heat density function and the milling temperature field. According to the calculated results and plotted graph, it is proven that the highest temperature is not on the knifepoint and host edge, in fact, it is offset from the host edge a certain space. So we can make the conclusion that the waved-edge milling insert’s cutting capability is higher than the flat milling insert’s which is consistent with the experimental result. All the studies above are the foundation for accurately describing the 3-D temperature field and optimizing groove.