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This article is concerned with the cutting forces and surface integrity in high-speed side milling of Ti-6Al-4V titanium alloy. The experiments were conducted with coated carbide cutting tools under dry cutting conditions. The effects of cutting parameters on the cutting forces, tool wear and surface integrity (including surface roughness, microhardness and microstructure beneath the machined surface) were investigated. The velocity effects are focused on in the present study. The experimental results show that the cutting forces in three directions increase with cutting speed, feed per tooth and depth of cut (DoC). The widths of flank wear VB increases rapidly with the increasing cutting speed. The surface roughness initially decreases and presents a minimum value at the cutting speed 200 m/min, and then increases with the cutting speed. The microstructure beneath the machined surfaces had minimal or no obvious plastic deformation under the present milling conditions. Work hardening leads to an increment in micro-hardness on the top surface. Furthermore, the hardness of machined surface decreases with the increase of cutting speed and feed per tooth due to thermal softening effects. The results indicated that the cutting speed 200 m/min could be considered as a critical value at which both relatively low cutting forces and improved surface quality can be obtained. 相似文献
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The aluminum alloy AlMn1Cu has been broadly applied for functional parts production because of its good properties. But few researches about the machining mechanism and the surface roughness were reported. The high-speed milling experiments are carried out in order to improve the machining quality and reveal the machining mechanism. The typical topography features of machined surface are observed by scan electron microscope(SEM). The results show that the milled surface topography is mainly characterized by the plastic shearing deformation surface and material piling zone. The material flows plastically along the end cutting edge of the flat-end milling tool and meanwhile is extruded by the end cutting edge, resulting in that materials partly adhere to the machined surface and form the material piling zone. As the depth of cut and the feed per tooth increase, the plastic flow of materials is strengthened and the machined surface becomes rougher. However, as the cutting speed increases, the plastic flow of materials is weakened and the milled surface becomes smoother. The cutting parameters (e.g. cutting speed, feed per tooth and depth of cut) influencing the surface roughness are analyzed. It can be concluded that the roughness of the machined surface formed by the end cutting edge is less than that by the cylindrical cutting edge when a cylindrical flat-end mill tool is used for milling. The proposed research provides the typical topography features of machined surface of the anti-rust aluminum alloy AlMn1Cu in high speed milling. 相似文献
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J. J. Junz Wang M. Y. Zheng 《The International Journal of Advanced Manufacturing Technology》2003,22(11-12):855-863
This paper investigates and compares the machining characteristics of AISI H13 tool steel in hardness states of 41 and 20 HRC in the ball end milling process. The machining characteristics are illustrated through three types of process outputs from the milling experiments: the milling force, the chip form, and the surface roughness. Characteristic differences in these process outputs are shown to reflect the hardness effect of the tool steel on the ball end milling process. The mechanistic phenomena of the milling process are revealed by the six shearing and ploughing cutting constants extracted from the milling forces. The experimental results show that all the cutting constants of the softer tool steel are greater than those of the hard steel, indicating that higher cutting and frictional energies are required in the chip shearing as well as in the nose ploughing processes of the softer tool steel. The higher cutting energy is also attested by the more severely deformed, shorter, and thicker chips of the softer steel. Surface roughness of the hard steel is shown to be considerably better than that of the soft steel at all cutting speeds and feed rates and is independent of cutting speed, whereas the surface roughness of the softer steel is significantly improved with increasing cutting speed. 相似文献
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Simulation and analysis of serrated chip formation in cutting process of hardened steel considering ploughing-effect 总被引:1,自引:0,他引:1
Fulin Wang Qi Tao Luoqiong Xiao Jiahao Hu Leilei Xu 《Journal of Mechanical Science and Technology》2018,32(5):2029-2037
A realistic finite element model considering the ploughing effect of cutting edge fillet was developed in high speed machining. Taking the hardened tool steel AISI D2 as the object of research, the cutting force and chip morphology were reasonably analyzed and compared with the actual results of cutting experiments, which verified the correctness of the model. Then, based on the model, the formation process of single serrated tooth was analyzed, while the effects of cutting heat and temperature field, material hardness and cutting speed on chip formation were explored. The research results indicate that: (1) The ploughing-effect has a great impact on the feed force, and for hardened tool steel AISI D2, the stagnation angle of 30o is more appropriate. (2) Also, stress concentration appears and shear slipping occurs along the shear plane in the process of serrated chip formation. The strain rate on the shear slipping surface is much greater than other places and the temperature gradient perpendicular to the shear plane is relatively higher. (3) The cutting force becomes larger with increasing the hardness value of workpieces, which causes the chip to more likely to produce serrated chips. (4) The fluctuation of cutting force is more significant as the cutting speed increases, which puts forward higher requirements for the tool and machine tool. 相似文献
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通过切削试验研究了高速铣削淬硬钢时刀具变量中的几何参数(铣刀的前角、后角、螺旋角)、工件变量(工件硬度)和切削参数变量(铣削速度、每齿进给量)对加工表面粗糙度的影响。根据对试验结果的分析得出高速铣削淬硬钢工件表面粗糙度的变化规律。 相似文献
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Inconel 718 is a typical difficult-to-machine material, and its high speed end milling process has wide applications in manufacturing parts from aerospace and power industry. Surface integrity of these parts greatly influences the final characteristics. This paper presents an experimental investigation to evaluate surface integrity behaviors in high speed end milling of Inconel 718 with finishing cutting parameters in terms of surface topography, surface roughness Ra, residual stresses, subsurface microstructure, and microhardness. The results show that abraded marks can be observed on the machined surfaces, and high cutting speed is advisable to get better surface topography and roughness quality. Due to high cutting temperature, residual stress is mainly high tensile stress. After increasing the cutting speed beyond 80m/min, the cutting forces hardly increased and the chips take away more cutting heat, which leads to that the residual stress barely increases. Microstructures in subsurface layers have only slight deformations after high speed milling, and there was also no obvious difference when the cutting speed increased beyond 80m/min against the microhardness in subsurface increases together with the cutting speed. 相似文献
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Effect of cutting speed on surface integrity and chip morphology in high-speed machining of PM nickel-based superalloy FGH95 总被引:1,自引:1,他引:0
Du Jin Zhanqiang Liu 《The International Journal of Advanced Manufacturing Technology》2012,60(9-12):893-899
High-speed machining is being recognized as one of the key manufacturing technologies for getting higher productivity and better surface integrity. FGH95 powder metallurgy superalloy is a kind of nickel-based superalloy which is produced by near-net-shape technology. With increasing demands for high precision and high performance of FGH95 components in aerospace industry, it is essential to recognize that the machined surface integrity may determine machined part service performance and reliability. Then, little is known about the machined surface integrity of this superalloy. Thus, the surface integrity in high-speed machining of FGH95 is investigated in this paper. Experiments are conducted on a CNC milling center with coated carbide tools under dry cutting conditions. The surface integrity is evaluated in terms of surface roughness, microhardness, and white layer. The influence of cutting speed on chip morphology is also investigated. Experiment results show that surface integrity and chip morphology of FGH95 are very sensitive to the cutting speed. When cutting speeds are below 2,400?m/min, the values of surface roughness have little variation, while when cutting speeds are in the range of 2,800–3,600?m/min, the values of surface roughness are higher than that of other cutting speeds. Severe work hardening is observed resulting from high-speed machining of FGH95 superalloy. The higher the cutting speed, the higher the surface hardness. When cutting speeds are in the range of 2,800–3,600?m/min, the white layer thickness is slightly higher than that of other cutting speeds. In high-speed machining of FGH95, the chip is segmented and has a typical sawtooth shape. The degree of serrated chip increases with the cutting speed. When the cutting speeds exceed 2,400?m/min, serrated chips change into fragment chips. 相似文献
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耐热钢Cr11MoV在拉削时,表面粗糙度较大,通过试验和分析,笔者认为这是拉削所产生的鳞刺现象,并提出了抑制鳞刺的几个方法:(1)使用含氯添加剂的切削液;(2)适当提高工件材料的硬度;(3)采用较低的拉削速度;(4)降低拉力前、后刀面的表面粗糙度,不留刃带。采取这些措施后,在拉削涡轮增压器的涡轮盘榫槽时,表面粗糙度降低了80%,拉刀的耐用度提高一倍以上。 相似文献
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选用涂层硬质合金刀具对300M超高强度钢进行高速铣削试验,通过单因素试验和多因素正交试验法,得出铣削参数(主轴转速、每齿进给量、铣削深度)对切削力及表面粗糙度的影响规律及主次关系。对正交试验结果做最小二乘法分析,建立切削力及表面粗糙度与铣削参数之间的经验模型;对经验模型的回归方程及系数做显著性检验,并对其进行参数优化,得出铣削参数的最优组合。结果表明:主轴转速和铣削深度对切削力的作用较大,而每齿进给量对其影响相对较弱;每齿进给量对表面粗糙度作用最强,铣削深度次之,主轴转速对其作用最弱。 相似文献
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Hamed Hassanpour Amir Rasti Javad Hashemi Khosrowshahi 《Machining Science and Technology》2020,24(5):719-738
AbstractIn this research, the effects of high speed milling on the main surface integrity characteristics, including surface roughness and topography, microhardness, white layer thickness, and surface chemical composition of Ti-6Al-4V were empirically studied. Totally, 18 experiments were carried out using a full factorial design of experiments method in the presence of minimum quantity lubricant. The results showed that by using high speed milling, it is possible to reach the surfaces with a higher quality and surface roughness of approximately 0.2?μm. Also, it was discovered that the microhardness variation with cutting speed has a dual nature. The maximum microhardness was obtained at the cutting speed of 375?m/min and the feed rate of 0.08?mm/tooth, which showed a 57% increase compared with the bulk material. In addition, by using the cutting speed of 450?m/min, the depth of heat-affected layer and work hardening effects declined up to 75% in comparison with the cutting speed of 300?m/min. 相似文献
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拉削加工过程中,刀齿在切削力、热耦合作用下较易产生磨损。由于高速拉削技术的发展,拉刀刀齿前刀面的磨损逐渐引起了更多的关注。随着拉削的进行,刀齿的磨损量不断增加。通过有限元分析,确定了拉削速度、齿升量、刀尖圆弧半径对前刀面磨损带深度和宽度的影响。 相似文献
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为有效控制和预测高硬度模具钢加工的表面质量和加工效率,通过设计正交切削试验,研究了在不同切削参数组合(主轴转速、进给速度、轴向切削深度和径向切削深度)及冷却润滑方式条件下、Ti Si N涂层刀具对模具钢SKD11(62HRC)的高速铣削。应用BP神经网络原理建立表面粗糙度预测模型,并进行试验验证其准确性。研究表明,在不同加工条件下,基于BP神经网络模型建立的涂层刀具铣削模具钢SKD11表面粗糙度模型有较好的预测精度,其预测误差在3.45%-6.25%之间,对于模具制造企业选择加工工艺参数、控制加工质量和降低加工成本有重要意义。 相似文献
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K. Kadirgama K. A. Abou-El-Hossein B. Mohammad H. Habeeb 《Journal of Mechanical Science and Technology》2007,21(10):1651-1655
The aim of this study is to develop the surface roughness prediction models, with the aid of statistical methods, for hastelloy
C-22HS when machined by PVD and CVD coated carbide cutting tools under various cutting conditions. These prediction models
were then compared with the results obtained experimentally. By using response surface method (RSM), first order models were
developed with 95 % confidence level. The surface roughness models were developed in terms of cutting speed, feed rate and
axial depth using RSM as a tool of design of experiment. In general, the results obtained from the mathematical models were
in good agreement with those obtained from the machining experiments. It was found that the feed rate, cutting speed and axial
depth played a major role in determining the surface roughness. On the other hand, the surface roughness increases with a
reduction in cutting speed. PVD coated cutting tool performs better than CVD when machining hastelloy C-22HS. It was observed
that most of the chips from the PVD cutting tool were in the form of discontinuous chip while CVD cutting tool produced continuous
chips. 相似文献