STUDY ON THE CUTTING FORCES DURING FACE MILLING OF A HARD STEEL

Claudiu Ionuț MALEA, Eduard Laurențiu NIȚU, Claudiu BĂDULESCU, Daniela Monica IORDACHE

Abstract


Hard steels are often used in the die and mold industry, but also in other industries, such as the automotive and naval industries. These types of steels have certain difficulties in their machining processes, which is why these aspects must be analysed and understood in order to correctly determine the cutting tools, the technological devices used, and the technological parameters utilised. In this paper, the process forces for face milling of hard 55NiCrMoV7 steel are analysed. An elastic device with strain gauge marks is used to measure the cutting forces in three directions, and a face-centered composite design is implemented, in which the cutting depth, feed per tooth, and cutting speed are varying. The results highlight the influences of cutting parameters on process forces based on dependency equations. The study provides theoretical and technical support for the analysis of face milling of hard steels.

Full Text:

PDF

References


Patel, R.D., Bhavsar, S.N., Experimental investigation during end milling of AISI D2 tool steel using AlCrN coated tool, Mater. Today: Proc, january 2020, 22:2647–56

Wang, R., Zhao, M., Mao, J., Liang, S.Y., Force Prediction and Material Removal Mechanism Analysis of Milling SiCp/2009Al. Micromachines, october 2022, 13(10):1687

Jarosz, K., Patel, K.V., Özel, T., Mechanistic force modeling in finish face milling of additively manufactured Inconel 625 nickel-based alloy, Int J Adv Manuf Technol, november 2020, 111(5):1535–51

Shnfir, M., Olufayo, O.A., Jomaa, W., Songmene V., Machinability Study of Hardened 1045 Steel When Milling with Ceramic Cutting Inserts, Materials, november 2019, 12(23):3974

Malea, C.I., Niţu, E.L., Iordache, M.D., Rizea, A.D., Experimental milling studies on hardened steels - a review, Int J Mod Manuf Technol. december 2021, 13:84–95

Nguyen, N.T., A development method of cutting force coefficients in face milling process using parallelogram insert, EUREKA Phys Eng, september 2021, (5):36–52

Kim, D.Y., Kim, D.M., Kwon, Ob., Park, H.W., Simulation of the round insert face milling process of AISI 316LN stainless steel with machining-based plastic behavior modeling, Proc Inst Mech Eng Part B J Eng Manuf. february 2021, 235(3):443–54

Alipanahi, A., Mahboubkhah, M., Barari, A., Cross-sensitivity control in a novel four-component milling dynamometer for simultaneous measurement of tri-axial forces and torque, Measurement, march 2022, 191

Zhou, C., Guo, K., Sun, J., An integrated wireless vibration sensing tool holder for milling tool condition monitoring with singularity analysis, Measurement, april 2021, 174

Gomez M.F., Schmitz T.L., Displacement-based dynamometer for milling force measurement, Procedia Manuf, january 2019, 34:867–75

Luo, M., Luo, H., Axinte, D., Liu, D., Mei, J., Liao Z., A wireless instrumented milling cutter system with embedded PVDF sensors, Mech Syst Signal Process, september 2018, 110:556–68

Li, Y., Zhao, Y., Fei, J., Qin, Y., Zhao, Y., Cai A., Gao S., Design and Development of a Three-Component Force Sensor for Milling Process Monitoring, Sensors, may 2017, 17(5):949

Qin, Y., Zhao, Y., Li, Y., Zhao, Y., Wang, P., A novel dynamometer for monitoring milling process, Int J Adv Manuf Technol, september 2017, 92(5):2535–43

Ting, Y., Chen, H.Y., Chen, J.H., Suprapto Yu, C.H., Design and performance evaluation of a multi-axis thin-film sensor for milling process measurement, Sens Actuators Phys, december 2021, 332

Kuntoğlu, M., Salur, E., Gupta, M., Sarıkaya, M., Pimenov, D., A state-of-the-art review on sensors and signal processing systems in mechanical machining processes Int J Adv Manuf Technol octomber 2021, 116

Gao, C., Bintao, S., Wu, H., Peng, M., Zhou, Y., New Tool Wear Estimation Method of the Milling Process Based on Multisensor Blind Source Separation, Math Probl Eng, july 2021, 2021

Li, B., Zhang, S., Wang, R., Fang, Y., Toward understanding of metallurgical behaviours in dry machining of hardened steel: phase transformation and surface oxidation, J Mater Res Technol, september 2019, 8(5):3811–21

Tien, D., Nguyen, N.T., Quy, T., Van Thien N., Cutting Forces and Surface Roughness in Face-Milling of SKD61 Hard Steel, Strojniski Vestn, june 2019, 65:375–85

Said, A.M., Ibrahim, G., Hamni, A., Suryaningsih, R., Burhanuddin, Y., Application of Central Composite Design for Optimization Machining Parameters When Machine Magnesium AZ 31, 2018, 7:10

Tamilarasan, A., Marimuthu, K., Multi-response optimisation of hard milling process parameters based on integrated Box-Behnken design with desirability function approach, Int J Mach Mach Mater, january 2014, 15(3–4):300–20

Azam, M., Jahanzaib, M., Wasim, A., Hussain, S., Surface roughness modeling using RSM for HSLA steel by coated carbide tools, Int J Adv Manuf Technol, may 2015, 78(5):1031–41

Myers, R.H., Montgomery, D.C., Anderson-Cook, C.M., Response Surface Methodology: Process and Product Optimization Using Designed Experiments, ISBN: 978-0470174463, 704 p, 3rd edition, Wiley, 2009


Refbacks

  • There are currently no refbacks.


JOURNAL INDEXED IN :