Abstract
Tool geometry has a direct impact on workpiece deformation, cutting forces, and tool wear, thereby affecting machinability, surface quality, and tool life. However, the research about the effect of cutter body geometry on cutting performance has rarely been reported. In this paper, the performance of the same series of indexable face-milling cutters with different diameters was investigated. The dynamic characteristic analysis results show that the cutter with diameter of 80 mm is the least susceptible to resonance due to the highest first-order modal frequency of 13,201 Hz. The cutter body geometry has a significant impact on mode shapes. The cutting performance tests show that the milling cutter with a diameter of 125 mm performs the best in terms of static force and maximum dynamic force in the Z direction and wear resistance. In view of the overall situation, the machined surface quality of the cutter with a diameter of 40 mm is the worst, whose abnormalities can be attributed to the vibration caused by the change of cutting depth and the formation and abscission of built-up edge. By the analysis of geometric structure, the center offset and the installation angle of indexable insert, together with the outline dimensions of the cutter body, jointly determine the tool cutting performance. The present work will provide guidance for the design of indexable milling cutters for high-performance machining of titanium alloys.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Ng EG, Szablewski D, Dumitrescu M, Elbestawi MA, Sokolowski JH (2004) High speed face milling of a aluminium silicon alloy casting. CIRP Ann Manuf Technol 53(1):69–72. https://doi.org/10.1016/S0007-8506(07)60647-7
Chen RY (2002) Principle of metal cutting. China Machine Press, Beijing
Yan X (2000) Research on the theory and methods of free-cutting tools design with applications. Dissertation, Huazhong University of Science and Technology
Liu ZQ (2006) Advanced tool design technology: tool structure, tool materials and coating technology. Aeronaut Manuf Technol 07:38–42. https://doi.org/10.3969/j.issn.1671-833X.2006.07.002
Han CL, Den CH, Zhao DF, Hu KH (2012) Milling performance of TiC-Ni cermet tools toughened by TiN nanoparticles. Int J Refract Met Hard Mater 30(1):12–15. https://doi.org/10.1016/j.ijrmhm.2011.06.005
Kim J, Kim M, Kang M, Kang S (2013) Material properties and tool performance of Ti-based solid solution cermets for micro end-mill applications. Int J Refract Met Hard Mater 36:278–282. https://doi.org/10.1016/j.ijrmhm.2012.10.005
Su HH, Liu P, Fu YC, Xu JH (2012) Tool life and surface integrity in high-speed milling of titanium alloy TA15 with PCD/PCBN tools. Chin J Aeronaut 25(5):784–790. https://doi.org/10.1016/S1000-9361(11)60445-7
Ogawa Y, Ota M, Nakamoto K, Fukaya T, Russell M, Zohdi TI, Yamazaki K, Aoyama H (2016) A study on machining of binder-less polycrystalline diamond by femtosecond pulsed laser for fabrication of micro milling tools. CIRP Ann Manuf Technol 65(1):245–248. https://doi.org/10.1016/j.cirp.2016.04.081
Lu L, Wang QM, Chen BZ, Ao YC, Yu DH, Wang CY, Wu SH, Kim KH (2014) Microstructure and cutting performance of CrTiAlN coating for high-speed dry milling. Trans Nonferrous Metals Soc China 24(6):1800–1806. https://doi.org/10.1016/S1003-6326(14)63256-8
Hei HJ, Ma J, Li XJ, Yu SW, Tang B, Shen YY, Tang WZ (2015) Preparation and performance of chemical vapor deposition diamond coatings synthesized onto the cemented carbide micro-end mills with a SiC interlayer. Surf Coat Technol 261:272–277. https://doi.org/10.1016/j.surfcoat.2014.11.019
Skordaris G, Bouzakis KD, Kotsanis T, Charalampous P, Bouzakis E, Lemmer O, Bolz S (2016) Film thickness effect on mechanical properties and milling performance of nano-structured multilayer PVD coated tools. Surf Coat Technol 307(A):452–460. https://doi.org/10.1016/j.surfcoat.2016.09.026
Aslantas K, Hopa HE, Percin M, Ucun İ, Çicek A (2016) Cutting performance of nano-crystalline diamond (NCD) coating in micro-milling of Ti6Al4V alloy. Precis Eng 45:55–66. https://doi.org/10.1016/j.precisioneng.2016.01.009
Liu W, Li AQ, Wu HD, Long Y, Huang JW, Deng X, Wang CY, Wang QM, Wu SH (2016) Effects of gas pressure on microstructure and performance of (Ti, Al, Zr)N coatings produced by physical vapor deposition. Ceram Int 42(15):17436–17441. https://doi.org/10.1016/j.ceramint.2016.08.045
Liu W, Chu QQ, Zeng JJ, He RX, Wu HD, Wu ZW, Wu SH (2017) PVD-CrAlN and TiAlN coated Si3N4 ceramic cutting inserts-2. High speed face milling performance and wear mechanism study. Ceram Int 43(12):9488–9492. https://doi.org/10.1016/j.ceramint.2017.04.127
Saptaji K, Subbiah S, Dhupia JS (2012) Effect of side edge angle and effective rake angle on top burrs in micro-milling. Precis Eng 36(3):444–450. https://doi.org/10.1016/j.precisioneng.2012.01.008
Subramanian M, Sakthivel M, Sooryaprakash K, Sudhakaran R (2013) Optimization of end mill tool geometry parameters for Al7075-T6 machining operations based on vibration amplitude by response surface methodology. Measurement 46(10):4005–4022. https://doi.org/10.1016/j.measurement.2013.08.015
Ji CH, Liu ZQ, Ai X (2014) Effect of cutter geometric configuration on aerodynamic noise generation in face milling cutters. Appl Acoust 75:43–51. https://doi.org/10.1016/j.apacoust.2013.07.004
Huang PL, Li JF, Sun J, Zhou J (2014) Study on performance in dry milling aeronautical titanium alloy thin-wall components with two types of tools. J Clean Prod 67:258–264. https://doi.org/10.1016/j.jclepro.2013.12.006
Warhanek M, Pfaff J, Martin P, Schönbächler L, Boos J, Wegener K (2016) Geometry optimization of polycrystalline diamond tools for the milling of sintered ZrO2. Procedia CIRP 46:290–293. https://doi.org/10.1016/j.procir.2016.04.003
Zhu ZL, Guo XL, Ekevad M, Cao PX, Na B, Zhu NF (2017) The effects of cutting parameters and tool geometry on cutting forces and tool wear in milling high-density fiberboard with ceramic cutting tools. Int J Adv Manuf Technol 91(9–12):4033–4041. https://doi.org/10.1007/s00170-017-0085-8
Ji W, Liu XL, Wang LH, Sun SL (2015) Experimental evaluation of polycrystalline diamond (PCD) tool geometries at high feed rate in milling of titanium alloy TC11. Int J Adv Manuf Technol 77(9–12):1549–1555. https://doi.org/10.1007/s00170-014-6517-9
Voss R, Seeholzer L, Kuster F, Wegener K (2016) Influence of fibre orientation, tool geometry and process parameters on surface quality in milling of CFRP. CIRP J Manuf Sci Technol 18:75–91. https://doi.org/10.1016/j.cirpj.2016.10.002
Uhlmann E, Riemer H, Schröter D, Sammler F, Richarz S (2017) Substitution of coolant by using a closed internally cooled milling tool. Procedia CIRP 61:553–557. https://doi.org/10.1016/j.procir.2016.11.267
Karpuschewski B, Kundrák J, Felhő C, Varga G, Sztankovics I, Makkai T, Borysenko D (2018) Preliminary investigations for the effect of cutting tool edge geometry in high-feed face milling. Vehicle Auto Eng 241–254. https://doi.org/10.1007/978-3-319-75677-6_20
(2012) Walter, General catalogue_ A compendium of expertise in machining
Tobias SA (1977) Machine-tool vibration. China Machine Press, Beijing
Li JZ (1993) Metal cutting dynamics. Zhejiang University Press, Zhejiang
Yang S, Tang HL, Liao BY (1983) Machine tool dynamics. China Machine Press, Beijing
Xiong LS, Yan XG, Zhang FR (2006) Fundamentals of mechanical manufacturing technology, 3rd edn. Huazhong University of Science and Technology Press, Wuhan
Acknowledgements
The authors are very grateful to the experimental platform provided by the advanced manufacturing and technology experiment center.
Funding
This research is financially supported by the National Science and Technology Major Project of China (grant no. 2012ZX04003-021).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Li, N., Chen, Y. & Kong, D. Effect of cutter body geometry in Ti-6Al-4V face-milling process. Int J Adv Manuf Technol 100, 1881–1892 (2019). https://doi.org/10.1007/s00170-018-2794-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2794-z