Experimental Evaluation of Cutter Orientation When Ball Nose End Milling Inconel 718™

High-speed machining (HSM), specifically end milling and ball end cutting, is attracting interest in the aerospace industry for the machining of complex 3D aerofoil surfaces in titanium alloys and nickel-based superalloys. Following a brief introduction on HSM and related aerospace work, the paper reviews published data on the effect of cutter/workpiece orientation, also known as engagement or tilt angle, on tool performance. Such angles are defined as ±β_fN and ±β_f.Experimental work is detailed on the effect of cutter orientation on tool life, cutting forces, chip formation, specific force, and workpiece surface roughness when high-speed ball end milling Inconel 718™. Dry cutting was performed using 8 mm diameter PVD-coated solid carbide cutters with the workpiece mounted at an angle of 45° from the cutter axis.A horizontal downward (-β_fN) cutting orientation provided the best tool life with cut lengths ∼50% longer than for all other directions (+β_fN, +β_f, and –β_f). Evaluation of cutting forces and associated spectrum analysis of results indicated that cutters employed in a horizontal downward direction produced the least vibration. This contributed to improved workpiece surface roughness, with typical mean values of ∼0.4 μm Ra as opposed to ∼1.25 μm Ra when machining in the vertical downward (–β_f) direction.     

An Approach to Theoretical Modeling and Simulation of Face Milling Forces

A new approach to theoretical modeling and simulation of face milling forces is presented. The present approach is based on a predictive machining theory in which machining characteristic factors in continuous cutting with a single-point cutting tool can be predicted from the workpiece material properties, tool geometry, and cutting conditions. The action of a milling cutter is considered as the simultaneous work of a number of single-point cutting tools, and the milling forces are predicted from input data of workpiece material properties, cutter parameters and tooth geometry, cutting condition, cutter and workpiece vibration structure parameters, and types of milling. A predictive force model for face milling is developed using this approach. In the model, the workpiece material properties are considered as functions of strain, strain rate, and temperature. The ratio of cutter tooth engagement over milling is taken into account for the determination of temperature in the cutting region. Cutter runout is included in the modeling for the chip load. The relative displacement between the cutter and workpiece due to the cutter and workpiece vibration is also included in the modeling to consider the effect on the undeformed chip thickness. A milling force simulation system has been developed using the model, and face milling experimental tests have been conducted to verify the simulation system. It is shown that the simulation results agree well with experimental results.     

Machining assessment of nano-crystalline hydroxyapatite bio-ceramic

Hydroxyapatite (HAP) is a widely used bio-ceramic in the fields of orthopedics and dentistry. This study investigates the machinability of nano-crystalline HAP (nHAP) bio-ceramic in end milling operations, using uncoated carbide tool under dry cutting conditions. Efforts are focused on the effects of various machining conditions on surface integrity. A first order surface roughness model for the end milling of nHAP was developed using response surface methodology (RSM), relating surface roughness to the cutting parameters: cutting speed, feed, and depth of cut. Model analysis showed that all three cutting parameters have significant effect on surface roughness. However, the current model has limited statistical predictive power and a higher order model is desired. Furthermore, tool wear and chip morphology was studied. Machined surface analysis showed that the surface integrity was good, and material removal was caused by brittle fracture without plastic flow.     

Experimental investigation of turning AISI 1045 steel using cryogenic carbon dioxide as the cutting fluid

The intensive temperatures in high speed machining not only limit the tool life but also impair the machined surface by inducing tensile residual stresses, microcracks and thermal damage. This problem can be handled largely by reducing the cutting temperature. When the conventional coolant is applied to the cutting zone, it fails to remove the extent of the heat effectively. Hence, a cryogenic coolant is highly recommended for this purpose. In this paper, an attempt has been made to use cryogenic carbon dioxide (CO₂) as the cutting fluid. Experimental investigations are carried out by turning AISI 1045 steel in which the efficiency of cryogenic CO₂ is compared to that of dry and wet machining with respect to cutting temperature, cutting forces, chip disposal and surface roughness. The experimental results show that the application of cryogenic CO₂ as the cutting fluid is an efficient coolant for the turning operation as it reduced the cutting temperature by 5%–22% when compared with conventional machining.It is also observed that the surface finish is improved to an appreciable amount in the finished work piece on the application of cryogenic CO₂. The surface finish is improved by 5%–25% in the cryogenic condition compared with wet machining.     

Parametric glass milling with simultaneous control

Parametric glass milling is presented to machine periodical circular channels on the glass plates for manufacturing micro testing devices. An end mill traverses in the linear motion during the workpiece rotation, which are synchronized by simultaneous control. The glass milling is controlled by 4 parameters in a mathematical model without NC program. Based on the principle of the parametric machining and the effect of the cutter axis inclination on the cutting process, a milling machine was developed to perform the parametric glass milling with an inclined ball end mill. The cutter axis inclination and the actual feed rate are associated with the critical feed rate, the maximum feed rate at which a crack-free surface is finished. As a machining example, a periodical circular channel was machined with a transparent surface by the simultaneous control.     

Experimental investigation of the machining induced residual stress tensor under mechanical loading

Residual stress induced by machining is complex and difficult to predict, since it involves mechanical loads, temperature gradients or phase transformation in the generation mechanism. In this work, an experiment with a statistical design for the residual stress tensor was performed to investigate the residual stress profile on a machined surface. In order to understand the generation mechanism of residual stress in machining, three variables and workpiece materials were carefully selected to focus on the mechanical loads and avoid the temperature gradients and phase transformation on the machined surface. The mechanical loads considered here included the chip formation force at the primary shear zone and the plowing force at the tool tip–workpiece contact. Depths of cut and rake angles were selected to alter the chip formation force, and the tool tip radius was designed to emphasize the plowing effect. The workpiece material was aluminum 3003. The experimental results showed that the chip formation force provides basic shapes of the residual stress profile for a machined surface. It decides the depth of the peak residual stress below the surface. However, the plowing force was the dominating effect on the surface residual stress, causing high stresses on the surface. The plowing force can shift the surface stress from tensile to compressive. Additionally, the measured stress tensor proved that in-plane shear stress exists for the machined surface.     

Ball end milling mechanistic model based on a voxel-based geometric representation and a ray casting technique

Prediction of machining forces involved in complex geometry can be valuable information for machine shops. This paper presents a mechanistic cutting force simulation model for ball end milling processes, using ray casting and voxel representation methods used in 3D computer graphics field. Using this method, instantaneous uncut chip cross sectional areas can be extracted, which can be used in cutting pressure coefficient extraction and machining simulation including machining forces and geometry of the workpiece. The major advantage of the proposed scheme is that it can simulate milling processes with arbitrary cutting tool geometry on a workpiece with complex geometry, using an algorithm with constant time complexity. A series of cutting experiments were carried out to validate the model.     

Micro dimple milling on cylinder surfaces

The paper presents a micro dimple machining on a cylinder surface with a two-flutes ball end mill. When the cutter axis is inclined and the depth of cut is less than the tool radius, non-cutting time, during which neither of the two cutting edges contacts the workpiece, appears in a rotation of the cutter. The rotation of the workpiece and the feed of the tool are controlled so that the cutting areas do not overlap each other. In order to incline the tool with respect to the tangential direction on the cylinder surface, the tool is located at a position oriented at 45° from the top of the cylinder. An analytical model is presented to control the shapes of the dimples with the cutting parameters. The presented machining is verified in cutting tests with measuring the shape and the profile of the dimples. Pre-machining operations are conducted to have a high cylindricity of the workpiece in longitudinal turning and polishing. The cutter runout of the tool is also eliminated by adjusting the orientation and the position of the tool in the collet chuck with measuring the cutting force. The micro dimples are machined accurately as they are simulated.     

The effect of spindle speed,feed-rate and machining time to the surface roughness and burr formation of Aluminum Alloy 1100 in micro-milling operation

This paper describes the characteristics and the cutting parameters performance of spindle speeds (n, rpm) and feed-rates (f, mm/s) during three interval ranges of machining times (t, minutes) with respect to the surface roughness and burr formation, by using a miniaturized micro-milling machine. Flat end-mill tools that have two-flutes, made of solid carbide with Mega-T coated, with 0.2 mm in diameter were used to cut Aluminum Alloy AA1100. The causal relationship among spindle speeds, feed-rates, and machining times toward the surface roughness was analyzed using a statistical method ANOVA. It is found that the feed-rate (f) and machining time (t) contribute significantly to the surface roughness. Lower feed-rate would produce better surface roughness. However, when machining time is transformed into total cut length, it is known that a higher feed-rate, that consequently giving more productive machining since produce more cut length, would not degrade surface quality and tool life significantly. Burr occurrence on machined work pieces was analyzed using SEM. The average sizes of top burr for each cutting parameter selection were analyzed to find the relation between the cutting parameters and burr formation. In this research, bottom burr was found. It is formed in a longer machining time compare the formation of top burr, entrance burr and exit burr. Burr formation is significantly affected by the tool condition, which is degrading during the machining process. This knowledge of appropriate cutting parameter selection and actual tool condition would be an important consideration when planning a micro-milling process to produce a product with minimum burr.     

Ruled Surface Machining on Five-Axis CNC Machine Tools

To achieve high precision and high productivity in machining sculptured surfaces, a new architecture for a five-axis CNC interpolator for machining ruled surfaces was developed and demonstrated on a milling machine. The objective of the five-axis interpolator is to continuously maintain the milling cutter axis in parallel with the straight lines of the ruled surface. The cutter position and orientation are calculated at each sampling period of the interpolator, and corresponding axial position commands are generated by an inverse kinematics algorithm. This real-time approach produces precise surfaces and requires substantially less machining time compared to the conventional off-line approach. Two new g-codes are also given in this paper for the new interpolator to produce part surfaces in CNC milling machines.     

Performance-Based Predictive Models and Optimization Methods for Turning Operations and Applications: Part 3—Optimum Cutting Conditions and Selection of Cutting Tools

This paper presents a summary of recent developments in developing performance-based machining optimization methodologies for turning operations. Four major machining performance measures (cutting force, tool wear/tool life, chip form/chip breakability, and surface roughness) are considered in the present work, which involves the development and integration of hybrid models for single and multi-pass turning operations with and without the effects of progressive tool wear. Nonlinear programming techniques were used for single-pass operations, while a genetic algorithms approach was adopted for multi-pass operations. This methodology offers the selection of optimum cutting conditions and cutting tools for turning with complex grooved tools.     

Analytical modelling of residual stresses in orthogonal machining of AISI4340 steel

Residual stress profile in a component is often considered as the critical characteristic as it directly affects the fatigue life of a machined component. This work presents an analytical model for the prediction of residual stresses in orthogonal machining of AISI4340 steel. The novelty of the model lies in the physics-based approach focusing on the nature of contact stresses in various machining zones and the effect of machining temperature. The model incorporates: (i) stresses in three contact regions viz. shear, tool-nose-work piece and tool flank and machined surface, (ii) machining temperature, (iii) strain, strain rate and temperature dependent work material properties, (iv) plastic stresses evaluation by two algorithms, S-J and hybrid, (v) relaxation procedure and (iv) cutting conditions. The model benchmarking shows (86–88%) agreement between the experimental and predicted residual stresses in the X- and Y-directions. On the machined surface, the tensile residual stresses decrease with an increase the edge radius and increase with an increase the cutting speed. However, below the surface, the compressive residual stresses increase with an increase the depth of cut. Further, it is observed that the proposed model with hybrid algorithm gives better results at a lower feed rate, whereas with the S-J algorithm, at a higher feed rate.     

Rotary ultrasonic machining of potassium dihydrogen phosphate (KDP) crystal: An experimental investigation on surface roughness

Potassium dihydrogen phosphate (KDP) crystal, widely used for important electro-optic parts, is a typical hard-to-machine material because of its soft, brittle, and anisotropic properties. High quality is usually required for machined surfaces on KDP parts. Reported machining methods for KDP crystal include diamond turning, grinding, magnetorheological finishing, and polishing. Each of these methods has its limitations. Therefore, it is desirable to develop new machining methods for KDP crystal. This paper presents an experimental investigation on surface roughness in rotary ultrasonic machining (RUM) of KDP. It was found that the surface roughness obtained when using a tool with a chamfered corner was lower than that obtained using tools with right-angle corners. Other process variables (spindle speed, feedrate, and ultrasonic power) also affected the surface roughness obtained.     

Effect of fluid concentration in titanium machining with an atomization-based cutting fluid (ACF) spray system

The aim of this work is to investigate the effect of metal-working fluid (MWF) concentration on the machining responses including tool life and wear, cutting force, friction coefficient, chip morphology, and surface roughness during the machining of titanium with the use of the ACF spray system. Five different concentrations from 5 to 15% of a water-soluble metalworking fluid (MWF) were applied during turning of a titanium alloy, Ti–6Al–4V. The thermo-physical properties such as viscosity, surface tension and thermal conductivity of these concentrations were also measured. The test results demonstrate that the tool life first extends with the increase in MWF concentration and then drops with further increase. At low concentration (e.g., 5%), a lack of the lubrication effect causes to increase in a higher friction at the tool–chip interface resulting in severe chipping and tool nose/flank wear within a short machining time. On the other hand, at high concentration, the cooling effect is less. This increases cutting temperature and a faster thermal softening/chipping/notching of the tool material and higher friction at the tool–chip–workpiece interaction zones resulting in early tool failure. A good balance between the cooling and the lubrication effects seems to be found at the 10% MWF concentration as it offers the best machining performance. However, machining with flood coolant is observed to perform the best in the range of 5–7%.     

Application of Taguchi method to selection of optimal lubrication and cutting conditions in face milling of AlMg3

This paper outlines the Taguchi optimization methodology, which is applied to optimize the cutting parameters in face milling when machining AlMg₃ (EN AW 5754) with HSS (high speed steel) tool under semi-finishing conditions in order to get the best surface roughness and the minimum power consumption. Beside the conventional flood lubrication, the investigations include the minimal quantity lubrication and the dry milling. These environment-friendly cutting techniques are considered two practical ways to the cleaner manufacturing in the context of the sustainable production. The parameters evaluated are the cutting speed, the depth of cut, the feed rate and the cooling lubrication techniques (cutting fluid flow). The appropriate orthogonal array, signal to noise (S/N) ratio and Pareto analysis of variance (ANOVA) are employed to analyze the effect of the mentioned parameters on the good surface finish (surface roughness). This paper illustrates the application of the techniques for single performance characteristics optimization, which employs the weighting factors to each of the S/N ration of the responses to obtain a multi-response S/N ratio for each trial of the orthogonal array and, finally, a single optimal process parameters setting. Using Taguchi method for the design of experiments (DOE), it is investigated the significant influence and the parameters interaction effect with minimum number of trials as compared with a full factorial design.     

Process capability study of laser assisted micro milling of a hard-to-machine material

Laser assisted micro milling (LAMM) is capable of generating three-dimensional micro scale features in hard-to-machine materials. This paper compares the process capability of LAMM with conventional micro milling of a hardened tool steel. In particular, the potential advantages of LAMM over micro milling with respect to cutting forces, tool wear, material removal rate, burr formation and surface roughness are investigated when micro milling hardened A2 tool steel (62 HRC). The results show that LAMM has significant advantages over micro milling, especially in terms of cutting forces, material removal rate and tool wear. The average reduction in the resultant cutting force is found to be up to 69% with laser assist. In addition, tool wear is found to be substantially less with laser assist even when the material removal rates are increased by a factor of six over the tool manufacturer recommended cutting conditions.     

Cryogenic Machining of Tantalum

A new approach for the machining of tantalum is presented. The new approach is a combination of traditional turning and cryogenically enhanced machining (CEM). In the tests, CEM was used to reduce the temperature at the cutting tool/workpiece interface, and thus reduce the temperature-dependent tool wear to prolong cutting tool life. The new method resulted in a reduction of surface roughness of the tantalum workpiece by 200% and a decrease of cutting forces by approximately 60% in experiments. Moreover, cutting tool life was extended up to 300% over that in the conventional machining.     

Surface modification of die steel materials by EDM method using tungsten powder-mixed dielectric

Surface modification by material transfer during electrical discharge machining (EDM) has emerged as a key research area in the last decade. Material may be provided to the machined surface of the workpiece by the eroding tool electrode or by using powder-mixed dielectric. Breakdown of the hydrocarbon dielectric contributes carbon to the plasma channel which may also cause surface modification. The present work has investigated the response of three die steel materials to surface modification by EDM method with tungsten powder mixed in the dielectric medium. Taguchi experimental design technique was used to conduct the experiments on each work material independently. Peak current, pulse on-time and pulse off-time were taken as variable factors and micro-hardness of the machined surface was taken as the response parameter. X-ray diffraction (XRD) and spectrometric analysis show substantial transfer of tungsten and carbon to the workpiece surface and an improvement of more than 100% in micro-hardness for all the three die steels. Presence of tungsten carbide (WC and W₂C) indicates that its formation is taking place in the plasma channel. Machining parameters for the best value of micro-hardness for each work material were found to be the same.     

Cutting tool temperatures in interrupted cutting—The effect of feed-direction modulation

Transient tool temperatures in interrupted machining processes were investigated. The initial focus was feed-direction modulated turning. Here, the instantaneous uncut chip thickness (IUCT) was modeled including the regenerative effect introduced by the modulation. Treating the tool as a one-eighth semi-infinite body, for a rectangular heat patch governed by the IUCT at the corner, the tool heat conduction problem was solved. The Green’s function solution procedure included heat convection from exterior surfaces. The results indicated that modulation lowered the cutting temperature, more significantly at a higher modulation frequency. However, heat conduction into the tool dominated over convection to the ambient. The IUCT was found to lag the peak temperature, indicating that modulation can possibly alter the thermal softening of the cutting tool in continuous cutting without a concomitant decrease in material removal rate. The same tool temperature model applied to face-milling indicated that the peak temperature occurred only at cut exit. Carefully planned interrupted hard-facing experiments were performed varying the frequency and duration of interruption. Tool-life data confirmed the beneficial effects of lower cutting temperatures due to slight interruption.     

Finite element modeling of microstructural changes in turning of AA7075-T651 Alloy

The surface characteristics of a machined product strongly influence its functional performance. During machining, the grain size of the surface is frequently modified, thus the properties of the machined surface are different to that of the original bulk material. These changes must be taken into account when modeling the surface integrity effects resulting from machining. In the present work, grain size changes induced during turning of AA7075-T651 (160 HV) alloy are modeled using the Finite Element (FE) method and a user subroutine is implemented in the FE code to describe the microstructural change and to simulate the dynamic recrystallization, with the consequent formation of new grains. In particular, a procedure utilizing the Zener–Hollomon and Hall–Petch equations is implemented in the user subroutine to predict the evolution of the material grain size and the surface hardness when varying the cutting speeds (180–720 m/min) and tool nose radii (0.4–1.2 mm). All simulations were performed for dry cutting conditions using uncoated carbide tools. The effectiveness of the proposed FE model was demonstrated through its capability to predict grain size evolution and hardness modification from the bulk material to machined surface. The model is validated by comparing the predicted results with those experimentally observed.