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1

Evaluation of Structural Powder Steel Properties after High-Temperature Thermomechanical Treatment and Finish Turning

Leksycki Kamil, Feldshtein Eugene, Maruda Radosław, Dyachkova Larisa, Szczotkarz Natalia, Zverko Alexandra

Advances in Science and Technology. Research Journal

|

2024

|

Vol. 18, no 1

26--35

EN

High-temperature thermo-mechanical processing (HTTMP) is a combination of plastic deformation and heat treatment operations. Such action makes it possible to increase metal mechanical properties resulting from both mechanical strengthening and heat treatment. As a result, it is possible to achieve high complex of operating characteristics of different types of steel and other alloys. However, there is a lack of information on the applicability of HTTMP of powder steel. These types of steel are very effective substitutes for traditional structural steel but are characterized by poor mechanical properties. This study considers the possibility of using HTTMP for powder steel frame additionally infiltrated by bronze with MoS2 addition to increase mechanical properties of the materials studied. Steel infiltrated, infiltrated and then hardened, infiltrated and then HTTMP treated with strain rates of 30, 50 and 70% were compared. The microstructural properties and hardness of the materials before machining were studied as well as the cutting forces and surface topography of those materials after turning with AH8015 carbide inserts. Cutting forces tests were realized with vc = 157 m/min, f = 0.25 mm/rev and ap = 0.25 mm. Surface topography tests were carried out with vc = 157 m/min, f = 0.25 mm/rev and ap = 0.25 mm. Constant cutting parameters were used to eliminate the effects of rest factors. It was found that the lowest cutting forces (Fc, Fp and Ff), surface roughness parameters (Sa and Sq) and small areas with single high peaks on the machined surface were obtained for infiltrated powder steel with subsequent HTTMP machining under 50% strain rate.

2

A review on machinability in the milling processes

Demirpolat Havva, Kuntoğlu Mustafa, Binali Rüstem

Sustainable Production, Instrumentation and Engineering Sciences

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2023

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vol. 1, nr 1

27--36

EN

This review paper focuses on the up-to-date machinability characteristics of milling processes such as cutting forces, surface roughness and tool wear and their impacts on the cutting mechanism. The methodology pur-sued in this paper is to analyze the previous research articles published between 2019–2022 classifying them into the subcategoriesthat usemill-ing operation as manufacturing strategy. As known, milling is one of the most used machining processes in industry and often applied for academic studiesforawide range of materials. Therefore, used sensor systems, main aim and the preferred methodology were summarized in the context of this paper. Seemingly, a great number of machinability papers have been published recently which focuses on the several types of engineering ma-terials and utilized various types of sensor system to improve the surface roughness and tool life. In addition, the investigation showed that optimi-zation approaches have been applied broadly to detect the best machining conditions. Also, it was observed that several modeling approaches such as finite element analysis is a good alternative to analyze the process.

3

Research on comprehensive performance of the arrangement of picks on the cutting head of the transverse-axis driving anchor machine

Huang Zhangfu, Lin Daiyong, Zhu ZM., Ning QM., Xu X., Jiang ZP.

Mining Science

|

2023

|

Vol. 30

7--26

EN

In this paper, the arrangement of picks on the cutting head of the transverse-axis driving anchor machine is analyzed and discussed, and two kinds of arrangement modes, namely sequential arrangement and punnett arrangement are studied. Based on the explicit dynamic analysis program ANSYS / LS-DYNA and the Holmquist-Johnson-Cook model, the contact mechanics characteristics between the pick and the rock are analyzed by using the theory and processing method of contact dynamics, rock mechanics and finite element. The maximum cutting force, average cutting force, cutting specific energy consumption and cutting force variance are obtained. By comparing the two groups of arrangement, it is concluded that the punnett arrangement is better than the sequential arrangement. Using MATLAB software to calculate the spectrum of cutting force, it is concluded that the main frequency is between 0 ~ 10Hz when the cutting head works.

4

Analytical study on the cutting force and residual stress in whirlwind milling of a large screw

Guo Qin, Wang Yulin, Zhou Bin

Journal of Theoretical and Applied Mechanics

|

2023

|

Vol. 61 nr 1

65--76

EN

The finite element method (FEM) is developed to simulate a discontinuous cutting in the whirlwind milling. Firstly, a simplified arc-cutting model for simulating the actual circular cutting, and a plane-cutting model for simplification were both developed and verified by experiments. Then, the effects of cutting parameters on the cutting force and residual stress were effectively investigated based on the plane-cutting model. Moreover, a plane-second- -cutting model was further developed. It showed that a minor decrease of cutting force and a higher maximum compressive stress were generated in the second cutting. Those results were conducive to predict and improve the whirlwind milling.

5

Analysing the impact of cutting force and vibration on surface roughness in external cylindrical grinding of SKH2 steel

Hoang Long, Nguyen Linh Tuan

Journal of Machine Engineering

|

2023

|

Vol. 23, No. 3

130--140

EN

The surface roughness of a part during external cylindrical grinding is directly impacted by cutting force and vibration, which are intermediate parameters. To improve the quality of finished parts, studying and controlling these parameters is essential. In this research, the Taguchi method combined with ANOVA analysis was utilized to analyse the effects of feed rate, cutting depth, and rotational speeds on cutting force and vibration amplitude. The test material used was SKH2 steel, which was heat-treated to a hardness of 60 HRC. The research aimed to investigate the relationship between cutting force, vibration, and surface roughness. The study concludes with an analysis of the influence of cutting force and vibration on the surface roughness of parts during external cylindrical grinding. The results show that as cutting force and vibration increase, the surface roughness of the workpiece in external grinding will also increase, and conversely when cutting force and vibration decrease, the surface roughness will decrease.

6

The performance of the cutting head of the longitudinal shaft anchor excavation machine based on the fuzzy number and entropy evaluation method

Zhang Zhengqi, Zhu Zongming, Qiao Shuo, Li Jian

Mining Science

|

2022

|

Vol. 29

75--98

EN

The longitudinal shaft anchor excavation machine is a new type of excavating machinery; the cutting head directly participates in cutting work. This paper focuses on the performance parameters of the cutting head. Two variables of the cutting head are selected to study, that is, the included the alloy head clip angle and the alloy head diameter. The installation angle of the pick is 55° and the section spac-ing is 60 mm. Three groups of data were selected for each variable, and the ANSYS finite element analysis software was used to simulate the rock cutting of the pick, and the load characteristics of the pick were obtained. The fuzzy number principle and entropy evaluation method are used to evaluate the load fluctuation, specific energy consumption, and pick load of three groups of data in each variable, and then the optimal performance parameters of the pick are obtained. The specific work is as follows: 1. Two parameter variables of the pick are selected and analyzed by LS-DYNA simulation software to obtain the cutting load of the pick at work. 2. Determine the index set and evaluation set of the cutting head, use the fuzzy number principle and entropy evaluation method to calculate the weight of each pa-rameter variable, create the fuzzy number relation evaluation matrix of performance parameters, and then use the fuzzy number comprehensive evaluation model to calculate the fuzzy number comprehensive evaluation result vector, finally get a set of optimal performance parameters of the pick. The final results show that the cutting head has the best performance when the alloy head clip angle is 100° and the alloy head diameter is 11 mm.

7

Investigation on rock cutting characteristics of spherical-tooth hob

Zhang Xuhui, Long Zhaomin, Liao Yashi, Long Jinjing, Liu Jifu

Mining Science

|

2022

|

Vol. 29

121--144

EN

To study the rock cutting characteristics of spherical-tooth hob, the rock cutting process induced by the spherical-tooth hob is analyzed based on the finite element simulation and the rock cutting experiments. Then the rock breaking states, rock cutting forces and rock cutting efficiency caused by the spherical-tooth hob under different penetrations are obtained. The results show that a cutting groove and a series of pits in the cutting groove will be produced when the penetration exceeds 9 mm. At such penetration, the spherical teeth and the cutter ring can cooperate to cut rock. The cutting forces curves show obvious fluctuation and the peak values of cutting forces correspond to the moment when a spherical tooth intrudes into the rock sample totally. The cutting forces increase with the growth of the penetration and the increase speed turns fast when the penetration exceeds 9 mm. With the increase of penetration, the specific energy consumption of the spherical tooth hob first decreases and then increases. It exists an optimal penetration of 12 mm to achieve the highest rock cutting efficiency.

8

Influence of reduced cutting speed values on operator safety and cutting tool life in the processes of manufacturing and regeneration of marine machinery parts

Labuda Wojciech, Charchalis Adam

Journal of KONBiN

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2022

|

Vol. 52, iss. 3

1--25

EN

The research used shafts made of X5CrNi18-10 (AISI 304L) stainless steel, which is used, among others in the shipbuilding industry. The turning process was carried out on the CU500MRD universal lathe with the use of cutting inserts with a corner radius of 0.2; 0.4 and 0.8 mm. The measurement of the forces during machining was recorded using a Kistler dynamometer. Surface roughness measurements were made with a Waveline W20 profilometer. The research results are the basis for determining the safe range of application of stainless steel cutting parameters on conventional lathes, with the simultaneous analysis of the quality of the machined surface.

PL

W badaniach wykorzystano wały wykonane ze stali nierdzewnej X5CrNi18-10 (AISI 304L), która znajduje zastosowanie między innymi w przemyśle okrętowym. Proces toczenia zrealizowano na tokarce uniwersalnej CU500MRD z wykorzystaniem płytek skrawających o promieniu naroża 0,2; 0,4 oraz 0,8 mm. Pomiar sił podczas obróbki skrawaniem rejestrowano z wykorzystaniem siłomierza firmy Kistler. Pomiary chropowatości powierzchni wykonano profilometrem Waveline W20. Wyniki badań są podstawą do wyznaczenia bezpiecznego zakresu stosowania parametrów skrawania stali nierdzewnej na tokarkach konwencjonalnych, przy jednoczesnej analizie jakości powierzchni obrobionej.

9

Experimental and Numerical Investigation of Cutting Forces and Temperatures in Milling of Custom 450 Steel

Gökçe Harun

Archives of Metallurgy and Materials

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2022

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Vol. 67, iss. 3

843--853

EN

Stainless steels have a wide usage field, their needs as structural parts are increasing day by day due to their resistance to corrosion and providing sufficient mechanical strength in environments that would cause corrosion. In addition to high mechanical properties of the stainless steels, the low heat transmission coefficients bring problems during machining. In this study, the suitable cutting tool and cutting parameters have been evaluated in terms of cutting forces and the tool temperature, the experimental results and finite element analysis have been compared in the milling of Custom 450 stainless steel which offers especially an excellent working opportunity at high temperature and salinity environment. Milling experiments have been carried out using L16 experimental design for Taguchi method. Four simulations have been made using finite element method with corresponding values in L16 orthogonal array for optimum cutting tool and the results were compared in terms of cutting forces and tool temperature changes.

10

Optimization of micromachining operation for particle reinforced UHMWPE composites

Sofuoğlu Mehmet Alper, Gürgen Selim

Archives of Civil and Mechanical Engineering

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2022

|

Vol. 22, no. 3

art. no. e138

EN

Unlike metals, polymers are highly affected by the heat generation during the machining of the workpiece, because the thermal conductivity of polymers are considerably lower than metals, and therefore heat is much more effective in the cutting zone. If the appropriate cutting parameters are not selected, the polymers become excessively deformed and the final part has high surface roughness, dimensionally large burr formation, or dimensional deviations. Machining of polymers ultra-high molecular weight polyethylene (UHMWPE) is quite common in industrial applications. In this study, the effect of SiC fillers on the machinability of UHMWPE polymer composite was investigated. First, different samples were produced using different filler sizes (1 μm, 50 μm, and 100 μm) and different filler amounts (1%, 3%, 5%). Micro-milling tests were carried out at a constant feed rate (70 mm/min), constant cutting depth (0.1 mm) and spindle speeds (1200, 2800, and 4400 rpm). Tool overhang lengths were selected as 10, 15, and 20 mm. During the experiments, the surface/burr shapes, cutting temperatures and cutting forces were observed. In general, it is observed that SiC filler reduces cutting forces and cutting temperatures. In the further stage of the study, Taguchi analysis was performed in the light of different SiC filler sizes, filler amounts, rotational speeds, and tool overhang lengths.

11

Path Interval and Its Relevance to Cutting Force in Ball and Filleted End Milling

Sekine Tsutomu

Advances in Science and Technology. Research Journal

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2022

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Vol. 16, no 1

85--94

EN

Computerized milling process is widely used in product manufacturing. Although manufacturing has gradually become highly-automated, the selection of machining conditions still remains an ever-present challenge in the process. To provide some findings contributable for the process planning, this study focuses on ball and filleted end milling. After brief explanations were given to the path interval determinations in both milling processes, the experiments were conducted to verify and characterize each procedure. The results of computational procedures showed good agreement with the experimental ones. Then, material removal rate and cutting force were analytically proposed for effective selection of machining conditions. The following findings were obtained from the demonstrations with discussion. Ball end milling required relatively large cutting force in the first tool path even though the material removal rate was comparatively small. On the contrary, filleted end mill enabled us to maintain a moderate cutting force in the first tool path even if the material removal rate expanded with increasing tool radius.

12

Cutting Forces and 3D Surface Analysis of CFRP Milling

Biruk-Urban Katarzyna, Józwik Jerzy, Bere Paul

Advances in Science and Technology. Research Journal

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2022

|

Vol. 16, no 2

206--215

EN

Due to the wide application of Carbon Fiber Reinforced Polymer (CFRP) composites in various industries, more and more attention is paid to machining these materials. One of the most popular way of machining composites is the milling. Milling of composite materials (CM) is a difficult technology due to their anisotropic and heterogeneous structure and the fact that the reinforcing fibers have an intense abrasive effect on the tool edge during machining. The appropriate selection of technological cutting parameters as well as the type and geometry of the tool can significantly affect the value of cutting forces during milling and the quality of the surface after machining. The aim of the paper is to assess the influence of used tools (differing in the number of cutting edges) and various technological parameters of surface milling of CFRP composites on the cutting forces occurring during machining and on the surface quality after machining. Cutting forces were measured during the milling process on a special stand produced by Kistler and the roughness measurements and surface structure were analyzed using the Alicona InfiniteFocusG5 3D optical microscope. On the basis of performed research it was found that 14 edge tool gives lower values of Fx and Fy components of the cutting forces comparing to 2 edge tool, which is especially noticeable at higher cutting speed values vc=160 m/min, where the values of Fx and Fy components decreased by about 43% at fz=0.0030 mm/tooth. This tool gives also lower values of the Sa roughness parameter 1.65 µm.

13

Optymalizacja topologiczna korpusów suportów obrabiarek specjalnych z uwzględnieniem sił skrawania

Śliwka Janusz, Pochopień Tomasz

Stal, Metale & Nowe Technologie

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2021

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nr 5-6

13--19

PL

W artykule przedstawiono metodę optymalizacji topologicznej wybranych korpusów układu suportowego obrabiarki do kolejnictwa. Na przykładzie suwaka głównego przeprowadzono optymalizację topologiczną mającą na celu zredukowanie objętości obszarów biernych. Obliczenia numeryczne uwzględniają działanie sił skrawania, zapewniając dostateczną sztywność węzła.

EN

he article presents a method of topology optimisation of the selected carriage bodies of a railway machine tool. Based on the example of the main slider, topology optimization was performed to reduce the volume of passive areas. Numerical calculations take into account the action of cutting forces, which ensures a sufficient rigidity of the node.

14

Experimental Investigation and Optimization of Machining Parameters in Turning of Aluminum Alloy 075-T651

Srivastava Arpit, Verma Mukesh Kumar, Niranjan Ramendra Singh, Chandra Abhishek, Patel Praveen Bhai

Production Engineering Archives

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2021

|

Vol. 27, Iss. 4

296--305

EN

Aluminum alloy 7075-T651 is a widely used material in the aviation, marine, and automobile sectors. The wide application marks the importance of this material’s research in the manufacturing field. This research focuses on optimizing input process parameters of the turning process in the machining of Aluminum 7075-T651 with a tungsten carbide insert. The input machining parameters are cutting speed, feed, and depth of cut for the output response parameters cutting force, feed force, radial force, material removal, and surface roughness of the workpiece. For optimization of process parameters, the Taguchi method, with standard L9 orthogonal array, is used. ANOVA is applied to obtain significant factors and optimal combinations of process parameters.

15

A tool wear condition monitoring approach for end milling based on numerical simulation

Zhu Qinsong, Sun Weifang, Zhou Yuqing, Gao Chen

Eksploatacja i Niezawodność

|

2021

|

Vol. 23, no. 2

371--380

EN

As an important research area of modern manufacturing, tool condition monitoring (TCM) has attracted much attention, especially artificial intelligence (AI)- based TCM method. However, the training samples obtained in practical experiments have the problem of sample missing and sample insufficiency. A numerical simulation- based TCM method is proposed to solve the above problem. First, a numerical model based on Johnson-Cook model is established, and the model parameters are optimized through orthogonal experiment technology, in which the KL divergence and cosine similarity are used as the evaluation indexes. Second, samples under various tool wear categories are obtained by the optimized numerical model above to provide missing samples not present in the practical experiments and expand sample size. The effectiveness of the proposed method is verified by its application in end milling TCM experiments. The results indicate the classification accuracies of four classifiers (SVM, RF, DT, and GRNN) can be improved significantly by the proposed TCM method.

16

Effect of thermal modification temperature of spruce wood on cutting parameters during circular saw blade cutting

Hlásková Luďka, Kopecký Zdeněk, Novák Vit

Annals of Warsaw University of Life Sciences - SGGW. Forestry and Wood Technology

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2021

|

No. 113

30--35

EN

Effect of thermal modification temperature of spruce wood on cutting parameters during circular saw blade cutting. The work examines the effect of temperature on energetical parameters (specific cutting resistance and cutting force) when cutting heat-treated wood of Norway spruce (Picea Abies) by a circular saw. The test samples were heat-treated at 160°C, 180°C, 200°C and 220°C. One sample was not heat treated and was used as a reference sample. In comparison with the theoretical assumptions, the influence of temperature on the cutting force and specific cutting resistance was confirmed. With increasing temperature of modification, the specific cutting resistance and cutting force decreased. The reduction of value of cutting force is related to changes in the chemical structure of the wood components, weight and density loss due to the increasing temperature of modification.

PL

Wpływ temperatury modyfikacji termicznej drewna świerkowego na parametry skrawania podczas cięcia piłą tarczową. W pracy zbadano wpływ temperatury modyfikacji na parametry skrawania (oprór skrawania i siła skrawania) przy cięciu piłą tarczową drewna świerka pospolitego (Picea Abies) poddanego obróbce termicznej. Próbki drewna do badań poddano obróbce w temperaturze 160°C, 180°C, 200°C i 220°C. Jako wariant kontrolny wykorzystano drewno naturalne (nie poddane obróbce termicznej). W ramach badan potwierdzono wpływ temperatury modyfikacji na siłę skrawania i opory skrawania drewna. Wraz ze wzrostem temperatury modyfikacji zmniejszały się wartosci oporu skrawania i siły skrawania. Zmniejszenie wartości siły skrawania związane jest ze zmianami struktury chemicznej składników drewna, ubytkiem masy i gęstości pod wpływem wzrostu temperatury modyfikacji.

17

Modeling of Vibration Behaviors of Turning Machining with the Constant Surface Speed Effect

Royandi Muhamad Aditya, Effendi Iman Apriana, Ibrahim Bustami, Hung Jui Pin

Advances in Science and Technology. Research Journal

|

2021

|

Vol. 15, no 3

134--145

EN

Turning machining is a complex process in which many variables can influence the desired results. Among those variables, cutting tool vibration and cutting force greatly affect the precision of the workpiece and the tool life. While the tool vibration and cutting force in feeding are primarily determined by cutting speed, feed rate, and depth of cut as well as the dynamic characteristics of the machining system. This paper presents an analytical modeling approach to investigate the effects of machining conditions based on the governing equation of the machining system. The machining behaviors under different conditions were simulated by Simulink block diagram. Basically, the cutting speed is considered the parameter dominating the vibration behavior and hence is served as the primary input for the simulation. The effectiveness of constant surface speed (CSS mode) or function G96 in the turning process was further examined through comparisons of the variations of vibration and cutting force generated in feeding with different conditions.

18

Wpływ parametrów modelu konstytutywnego Johnsona-Cooka na wyniki symulacji numerycznych procesu skrawania

Löschner P., Jarosz K.

Zeszyty Naukowe. Mechanika / Politechnika Opolska

|

2018

|

z. 109

57--64

PL

W artykule zaprezentowano wpływ wartości parametrów modelu konstytutywnego Johnsona–Cooka na wyniki symulacji MES procesu toczenia. W symulacjach użyte zostały cztery dostępne w literaturze zestawy parametrów modelu J–C dla stopu tytanu Ti6Al4V. Wyniki symulacji zostały porównane pod kątem otrzymanych wartości siły skrawania, rozkładu naprężeń oraz postaci wióra. Odnotowano znaczący wpływ wartości parametrów modelu J–C na wyniki symulacji.

XX

The article presents the effect of different sets of Johnson–Cook constitutive model parameters on the results of an FEM turning process simulation. Four different sets of parameters available for Ti6Al4V titanium alloy taken from open literature were used. Simulation results were compared on the account of cutting force, stress distribution and chip shape. The research has shown a substantial effect of J–C model parameter values on simulation results.

19

Monitorowanie sił skrawania podczas toczenia

Nosol A., Bartoszuk M.

Obróbka Metalu

|

2018

|

nr 3

30--35

EN

It is well known that machining is the basic technique for manufacturing machine parts. Over the years, the machining processes have intensified, and what is more, the machining of difficult-to-cut materials, such as nickel and titanium alloys, has become more and more popular. For this reason, the process of cutting is not fully understood. Therefore, knowledge of the distribution of cutting forces and phenomena occurring in the cutting zone allows, for example, for optimization of cutting parameters and monitoring of tool wear. In the literature, the measuring devices for the total cutting force components were rarely described. For this reason, the authors have decided to explore the subject in greater depth. This article presents examples of constructions of turning actuators and comparison of results obtained for strain gauges of own design and professional piezoelectric actuator for the same machining parameters.

PL

Powszechnie wiadomo, że obróbka skrawaniem jest podstawową techniką wytwarzania części maszyn. Z biegiem lat zauważalna jest intensyfikacja procesów obróbki, co więcej – coraz częściej obrabiane są materiały trudnoskrawalne, np. stopy niklu i tytanu. Z tego powodu proces ich skrawania nie do końca jest poznany. Znajomość rozkładu sił skrawania i zjawisk występujących w strefie skrawania pozwala np. na optymalizację parametrów skrawania oraz na monitorowanie zużycia narzędzia. W literaturze fachowej urządzenia do pomiaru składowych całkowitej siły skrawania były rzadko opisywane. Z tego powodu autorzy postanowili zgłębić ten temat. Artykuł niniejszy przedstawia przykładowe konstrukcje siłomierzy tokarskich oraz porównanie wyników uzyskanych dla siłomierzy tensometrycznych własnej konstrukcji i profesjonalnego siłomierza piezoelektrycznego dla tych samych parametrów obróbki.

20

Wpływ wybranych warunków skrawania na siłę i moment podczas wiercenia żeliwa szarego

Miko E., Nowakowski Ł., Skrzyniarz M.

Mechanik

|

2018

|

R. 91, nr 8-9

760--762

PL

Przeanalizowano wpływ wybranych parametrów skrawania (prędkości i posuwu) na moment i siłę skrawania podczas wiercenia żeliwa EN-GJL-250. Operacja wiercenia została wykonana wiertłem składanym firmy Allied Machine z serii DEM22000S-20FM, na pionowym centrum frezarskim Hermle B300. Pomiar momentu i siły skrawania podczas wiercenia przeprowadzono siłomierzem firmy Kistler.

EN

The impact of selected cutting parameters (cutting speed and cutting feed) on the torque and cutting force during drilling gray cast iron EN-GJL-250 was analyzed. The drilling operation was carried out by Allied Machnie drill series: DEM22000S-20FM, on the Hermle B300 vertical milling center. The measurement of the torque and the cutting forces during drilling was carried out by Kistler device.