Experimental study on chatter of micro-miniature turn-milling

A chatter experiment of micro-miniature turn-milling was carried out in this paper. In or- der to reduce the effect that the natural frequencies of workpieces brought to the chatter experiments of micro-miniature turn-milling, both positive and negative cone-shape workpieces were used . The chatter frequency of micro-miniature turn-milling process was obtained by the sampling and analyzing systems. Then by applying excitation experiments to the workpiece system and tool system respec- tively, the natural frequencies of these two systems were obtained. By comparing chatter frequency of micro-miniature turn-milling process with the natural frequencies of workpiece system and tool system, we found that chatter frequency of micro-miniature turn-milUng was close to the natural fre- quency of the low stiffness vibration body in the machine tool system. The funding could be useful for optimizing the structure of machine-tool and designing the machining process.

Research on Machined Surface Veins Based on Turn-milling Technology

Turn-milling which history dates from the end of the 20th century is one of the advanced metal cutting technologies. It could precisely machine hard materials as an alternative to turning for certain limitations. A series of orthogonal turn-milling surface veins experiments have been done on the turn-milling machining center by machining aluminum alloy,and then the nexus between the surface veins and the cutting regimes is studied. The mathematical model for surface vein direction angle is established,also the forming mechanics of surface vein direction is analyzed. Its variety regulation presents decreasing trend with as axial feed and cutter rotary speed increasing. For different eccentric distance of orthogonal turn-milling,the surface veins are different.

Experimental investigation of cutting parameters in machining of 100Cr6 with tangential turn-milling method

The turn-milling methods for machining oper- ation have been developed to increase efficiency of con- ventional machines recently. These methods are used especially by coupling some apparatuses on the computer numerical control （CNC） machine to decrease the pro- duction time and machine costs, ensure the maximum production and increase the quality of machining. In this study, 100Cr6 bearing steel extensively used in industry has been machined by tangential turn-milling method. This paper presents an approach for optimization of the effects of the cutting parameters including cutter speed, workpiece speed, axial feed rate, and depth of cut on the surface roughness in the machining of 100Cr6 steel with tangential turn-milling method by using genetic algorithm （GA）. Tangential turning-milling method has been determined to have optimum effects of cutting parameters on the machining of 100Cr6 steel. The experimental results show that the surface roughness quality is close to that of grinding process.

Machinability of damage-tolerant titanium alloy in orthogonal turn-milling

The damage-tolerant titanium alloy TC21 is used extensively in important parts of advanced aircraft because of its high strength and durability. However, cutting TC21 entails problems, such as high cutting temperature, high tool tip stress, rapid tool wear, and difficulty guaranteeing processing quality. Orthogonal turn-milling can be used to solve these problems. In this study, the machinability of TC21 in orthogonal turn-milling is investigated experimentally to optimize the cutting parameters of orthogonal turn-milling and improve the machining efficiency, tool life, and machining quality of TC21. The mechanism of the effect of turn-milling parameters on tool life is discussed, the relationship between each parameter and tool life is analyzed, and the failure process of a TiAlN-coated tool in turn-milling is explored. Experiments are conducted on the integrity of the machined surface (surface roughness, metallographic structure, and work hardening) by turn-milling, and how the parameters influence such integrity is analyzed. Then, reasonable cutting parameters for TC21 in orthogonal turn-milling are recommended. This study provides strong guidance for exploring the machinability of difficult-to-cut-materials in orthogonal turn-milling and improves the applicability of orthogonal turn-milling for such materials.

Variable eccentric distance-based tool path generation for orthogonal turn-milling

This study proposes an algorithm for max- imizing strip width in orthogonal tum-miUing based on variable eccentric distance. The machining error model is first established based on the local cutting profile at the contact line. The influencing factors of the strip width are then investigated to analyze their features and determine an optimizing strategy. The optimized model for maximum machining strip width is formulated by adopting a variable eccentric distance. Hausdorff distance and Fr6chet distance are introduced in this study to implement the constraint function of the machining error in the optimized model. The computing procedure is subsequently provided. Simulations and experiments have been conducted to verify the effectiveness of the proposed algorithm.

State of the art in finite element approaches for milling process:a review

Over a century,metal cutting has been observed as a vital process in the domain of manufacturing.Among the numerous available metal-cutting processes,milling has been considered as one of the most employable processes to machine a variety of engineering materials productively.In the milling process,material removal occurs when the workpiece is fed against a rotating tool with multiple cutting edges.In order to maximize the profitability of metal cutting operations,it is essential that the various input and output variable relationships are analyzed and optimized.The experimental method of studying milling processes is costly and time demanding,particularly when a large variety of elements such as cutting tool shape,materials,cutting conditions,and so on,are included.Due to these issues,other alternatives emerged in the form of mathematical simulations that employ numerical methods.The finite element approaches have well-proven to be the most practical and commonly utilized numerical methods.The finite element model(FEM)can be used to determine the various physical interactions occurring during the machining process along with the prediction of various milling characteristics,such as cutting forces,cutting temperature,stresses,etc.,with the help of milling inputs.In the present article,various research studies in the broad milling process domain practiced with numerous finite element approaches have been critically reviewed and reported.It further highlights the several experimental and finite element approaches-based research studies that attempted to analyze and optimize the overall performance of the different milling processes.In recent years,various investigators have explored numerous ways to enhance milling performance by probing the different factors that influence the quality attributes.Some of the studies have also been found to be focused on the economic impacts of milling and various process inputs that affect milling performance.Furthermore,various milling factors’impact on the performance characteristics are presented and critically discussed.The issues related to the recent improvements in tool-work interaction modeling,experimental techniques for acquiring various milling performance measures,and the aspects of turn and micro-milling with finite element-based modeling have been further highlighted.Among the various available classifications in the milling process as employed in industries,face milling is more strongly established compared to other versions such as end milling,helical milling,gear milling,etc.The final section of this research article explores the various research aspects and outlines future research directions.