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1

Investigation of the Impact of Face Milling Parameters on the Roughness of the Machined Surface for 1.4301 Steel

Bembenek Michał, Dzienniak Damian, Dzindziora Agnieszka, Sułowski Maciej, Ropyak Liubomyr

Advances in Science and Technology. Research Journal

|

2023

|

Vol. 17, no 4

299--312

EN

The objective of this research was to analyze how different milling parameters impact the roughness of the surface produced during the machining process. Kinematic parameters, such as cutting speed and feed per tooth, as well as geometric parameters, such as axial and radial depth of machining, were considered in various configurations to determine which one had the greatest impact on the surface quality of 1.4301 stainless steel (also known as AISI 304, among other designations). This type of steel is commonly used in a number of industries, such as construction, automotive, food, chemical, decoration, oil, and petrochemical, owing to its favorable properties. It is also relatively cheap. The analyzed roughness parameters included Ra, Rq, Rz, Rt, which, considered collectively, provide a comprehensive picture of the overall surface quality. Based on the results, feed per tooth is the one parameter that was to a large degree responsible for the overall quality roughness of the surface of the analyzed samples. The remaining tested parameters also had an impact on the surface quality, which resulted in a dynamic increase or decrease in roughness (extremes), but not to the same degree as in the case of feed per tooth. At one point, for a relatively low axial depth of cut, a sudden increase in the resulting roughness was recorded.

2

Effect of Friction Machining on Low Carbon Steel with Titanium Traces in terms of Surface Hardening

Sheikh Ali R.

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 4

41--46

EN

This work is an experimental study of thermo-mechanical surface hardening of mild steel with trace elements like titanium in negligible concentrations. This is somewhat an advanced technique used to harden steel surface which can be hardened in many typical ways. The concept is combining the thermal as well as mechanical technique to attain better results. It is quite obvious that mechanical refers to the compressive loading during machining and thermal refers to producing heat on the surface of work piece. The ideal conditions are when the heat produced is enough to achieve austenite and then subsequent quick cooling helps in the formation of marten site, which is metallurgically the most highly strong phase of steel, in terms of hardness. The coolant used preferably is the emulsified oil which flows on the surface during machining with variable rate of flow as the optimum effect is. This process hardens the surface of steel and increases its resistance against wear and abrasion. Preference is to achieve surface hardening using the conventional equipment so that operational cost is kept low and better results are attained. This technique has been quite successful in the laboratory. It can be termed as friction hardening. Some improvements in the process scheme and working environment can be made to get better results.

3

Effect of Face Milling Parameters of Carbon Fiber Reinforced Plastics Composites on Surface Properties

Miturska-Barańska Izabela, Józwik Jerzy, Bere Paul

Advances in Science and Technology. Research Journal

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2022

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Vol. 16, no 2

26--38

EN

This paper analyses the influence of face milling process parameters on the surface properties of carbon fibre reinforced polymer. The influence of milling speed and feed per tooth on the surface properties was determined. The influence of cutting speed and feed per tooth on surface energy properties was determined. The object of research was a carbon fiber reinforced plastics (CFRP) composites plate made of carbon fibre in epoxy matrix. The tool used in the study was a double-edged end mill. The machining parameters used were variable: cutting speeds of 100 m·min-1, 120 m·min-1, 140 m·min-1 and 160 m·min-1, and feeds per tooth of 0.015 mm/tooth, 0.020 mm/tooth, 0.025 mm/tooth and 0.03 mm/tooth. The axial depth of cut and radial depth of cut was a constant parameter. After milling, tests were carried out on the surface contact angle, which was used to determine the surface free energy. Based on the contact angle measurements carried out with the sitting-drop method and the calculation of the surface free energy with the Owens-Wendt model, it was observed, that the increase in the value of the surface free energy is significantly influenced by the increase in the cutting speed.

4

The possibilities to reduce surface roughness in pre-assembly face milling with Wiper inserts

Frączyk Adam

Technologia i Automatyzacja Montażu

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2020

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nr 1

52--56

EN

In the paper, the results of the comparative studies of the surface roughness, as obtained after face milling, with the application of standard cutting inserts and Wiper inserts, have been discussed. The presented results of the studies show in what technological conditions it is possible to obtain the best effects of reducing the surface roughness.

PL

W artykule przedstawiono wyniki badań porównawczych chropowatości powierzchni, uzyskanych po obróbce frezowania czołowego, przy wykorzystaniu standardowych płytek skrawających oraz płytek typu Wiper. Zaprezentowane rezultaty badań pokazują, w jakich warunkach technologicznych obróbki można uzyskać najlepsze efekty obniżenia chropowatości powierzchni.

5

An assessment of applicability of the two-dimensional wavelet transform to assess the minimum chip thickness determination accuracy

Gogolewski Damian, Makieła Włodzimierz, Nowakowski Łukasz

Metrology and Measurement Systems

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2020

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Vol. 27, nr 4

659--672

EN

The objective of the study was to assess the potential use of optical measuring instruments to determine the minimum chip thickness in face milling. Images of scanned surfaces were analyzed using mother wavelets. Filtration of optical signals helped identify the characteristic zones observed on the workpiece surface at the beginning of the cutting process. The measurement data were analyzed statistically. The results were then used to estimate how accurate each measuring system was to determine the minimum uncut chip thickness. Also, experimental verification was carried out for each mother wavelet to assess their suitability for analyzing surface images.

6

Methods of comparison of surface texture based on fractal dimension and Hotelling’s T2 test

Gogolewski Damian

Journal of Machine Engineering

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2019

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Vol. 19, No. 4

82--90

EN

Comparative analysis of the surface texture of machine parts can be successfully carried out using statistical tests. The paper presents a methodology of method used to compare the surface texture by applying Hotelling’s T2 test as well as a method used to evaluate surface topography by applying fractal dimension. The tests were carried out on samples produced with the use of face milling process for four types of materials. The following types of steel were used: 40HM, C45, NC6 and WCL. For each type of material, four areas were machined with the same machining parameters. Based on these results a decision was made whether the surfaces, despite the same machining conditions, were significantly different from each other. Furthermore, the analysis indicated that the fractal dimension enabled to characterise signal irregularities in quantitative and qualitative way.

7

Wpływ parametrów technologicznych w procesie frezowania stali EZ6NCT25 na wybrane wskaźniki skrawalności

Skoczylas A., Zaleski K.

Mechanik

|

2018

|

R. 91, nr 8-9

772--774

PL

W artykule przedstawiono wyniki badań momentu skrawania i chropowatości powierzchni w procesie frezowania czołowego stali EZ6NCT25. Stal EZ6NCT25, zaliczana do stali nierdzewnych, jest z powodzeniem wykorzystywana w przemyśle lotniczym i okrętowym. Wytwarza się z niej takie elementy, jak łopatki turbin czy zespoły komory spalania. W eksperymencie wykorzystano narzędzia monolityczne pełnowęglikowe o średnicy d = 12 mm. Badania przeprowadzono przy zmiennych parametrach technologicznych. Zauważono, że parametry te wpływają na moment skrawania i amplitudę momentu oraz – w mniejszym stopniu – na chropowatość powierzchni.

EN

The paper reports results of an investigation of the cutting torque and surface roughness in the face milling of EZ6NCT25 steel. Classified as stainless steel, EZ6NCT25 is effectively used in the aviation and shipbuilding industries. This steel grade is used for producing elements such as turbine blades and combustion chamber assemblies. Experimental tests were performed with the use of full-carbide monolithic tools with the diameter of d = 12 mm. The tests were conducted at variable technological parameters. It has been observed that that cutting torque and amplitude cutting torque depend on machining conditions, and also, although to a lesser extent the surface roughness.

8

Effect of temperature of heat treatment on energetic intensity of flat milling of picea abies

Koleda P., Korčok M., Barcík S., Iľaš S.

Management Systems in Production Engineering

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2018

|

nr 3 (26)

151--156

EN

The paper deals with the research of the influence of thermal modification temperature of spruce wood on the electric energy consumption of its face milling. Samples of spruce wood heat treated at temperatures of 160, 180, 200 and 220°C were milled at the cutting speed of 20, 40 and 60 m.s-1, the feed rate of 6, 10 and 15 m.min-1, the rake angle of 15° with the depth of the cut of 1 mm. The energy consumption was evaluated from the cutting power, which was based on the difference during milling and idle cycle. The analysis of variance showed a decrease in cutting power with an increasing temperature of thermal modification. The average cutting power value is 137.7 W at the native sample and 80.8 W at the sample treated at 220°C. The Duncan’s test of statistical significance has shown that the thermal modification has a statistically significant effect on the cutting power values.

9

The effect of alternative cutter paths on flatness deviations in the face milling of aluminum plate parts

Dobrzynski M., Chuchala D., Orlowski K. A.

Journal of Machine Engineering

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2018

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Vol. 18, No. 1

80--87

EN

In this paper the relationships between the alternative machining paths and flatness deviations of the aluminum plate part, were presented. The flatness tolerance of the main surface of the plate part has crucial meaning due to the assembly requirement of piezoelectric elements on the radiator. The aluminum bodies under investigation are the base part of the radiators with crimped feathers for the train industry. The surface of the aluminum plate part was milled using three different milling strategies: along of longer or shorter side of workpiece and at an angle of 45°. The aluminum bodies were machined on milling centre ecoMILL 70 DMG MORI. The flatness deviation measurements were carried out on the Coordinated Measuring Machine Altera 7.5.5 Nikon Metrology NV. These measurements were made during the manufacturing process of the radiator, namely after machining, however, before the process crimping of feathers. The results that were obtained enables the validation of assumed milling path strategies in connection of the subsequent machining and assembly processes.

10

A comparative study of face milling of D2 steel using AL2O3 based nanofluid minimum quantity lubrication and minimum quantity lubrication

Ahsan Ul Haq Muhammad, Khan Aqib Mashood, Gong Le, Xu Tao, Meng Longhui, Hussain Salman

Advances in Science and Technology. Research Journal

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2018

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Vol. 12, no 1

99--105

EN

This study aims to investigate the effects of process parameters: feed, depth of cut and flow rate, on the temperature during face milling of the D2 tool steel under two different lubricant conditions, Minimum Quantity Lubrication (MQL) and Nano fluid Minimum Quantity Lubrication (NFMQL). Deionized water with the flow rate range 200–400 ml/h was used in MQL. 2% by weight concentration of Al2O3 nano particles with deionized water as a base fluid used as NFMQL with the same flow rate. Response surface methodology RSM central composite design CCD was used to design experiment run, modeling and analysis. ANOVA was used for the adequacy and validation of the system. The comparison shows that NFMQL condition reduced temperature more efficiently during machining.

11

Optimization of CNC face milling process of Al-6061-T6 aluminum alloy

Jarosz K., Löschner P., Niesłony P., Krolczyk G.

Journal of Machine Engineering

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2017

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Vol. 17, No. 1

69--77

EN

In modern machining industry, the use of computer software is an integral element in the design of technological processes. This work aims to present possibilities for optimization of milling operations with the use of commercial software designed especially for that use. A face milling operation of an aluminium flange was chosen for this study. Several different optimization strategies were described and their results shown, analysed and discussed. The effect of variable radial depth of cut on cutting force values in milling processes was reflected upon. Additionally, further research involving comparison of experiment results with simulation was proposed. It was proven that correct optimization strategy can reduce machining time for the analysed face milling operation about 37% without exceeding imposed process parameter constraints.

12

Zastosowanie dwuwymiarowej transformaty falkowej do oceny chropowatości powierzchni frezowanych

Makieła W., Gogolewski D.

Mechanik

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2016

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R. 89, nr 11

1627--1629

PL

Przedstawiono wyniki analizy chropowatości powierzchni z wykorzystaniem dwuwymiarowej transformaty falkowej. Badaniom poddano powierzchnie powstałe w procesie frezowania czołowego elementów ze stali 40HM. Wykazano, że poszczególne postaci falki bazowej mają zdolność do wykrywania charakterystycznych obszarów w sygnałach niestacjonarnych, jednak uwidaczniają powstałe wady powierzchni z różną intensywnością.

EN

In this paper, authors present the research results of surface roughness analysis using the two-dimensional wavelet transform. The tests have been carried out on surface of 40HM steel produced in face milling process. The research results show the particular mother wavelet has ability to detect specific areas in non-stationary signals, however, they highlight the surface defects with different intensity.

13

Wyznaczanie minimalnej grubości warstwy skrawanej z wykorzystaniem dwuwymiarowej transformaty falkowej

Makieła W., Gogolewski D., Nowakowski Ł.

Mechanik

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2016

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R. 89, nr 11

1632--1633

PL

W pracy podjęto próbę adaptacji dwuwymiarowej transformaty falkowej do identyfikacji występowania strefy inicjowania procesu skrawania oraz wyznaczenia wartości minimalnej grubości warstwy skrawanej dla procesu frezowania czołowego stali C45. Otrzymane wyniki wskazują na zdolność transformaty falkowej do analizy sygnałów niestacjonarnych oraz wykrywania w nich obszarów charakterystycznych.

EN

In this paper, authors take attempt to adapt the two-dimensional wavelet transform to identify the cutting zones and the determination of a minimum thickness value of the machined layer in the process of face milling of steel C45. The research results show the ability of the wavelet transform for the analysis of non-stationary signals and detecting characteristics zones in surface.

14

Metoda oceny wpływu posuwu na proces frezowania czołowego z użyciem dwuwymiarowej transformaty falkowej

Makieła W., Gogolewski D.

Mechanik

|

2016

|

R. 89, nr 8-9

1086--1087

PL

Przedstawiono wyniki analizy struktury geometrycznej powierzchni. Zbadano możliwość adaptacji transformaty falkowej do wyznaczenia wartości parametru posuwu na obrót podczas procesu frezowania czołowego dla sześciu rodzajów materiału. Do badań użyto falki Morlet oraz Mexican hat. Stwierdzono, że ciągła transformata falkowa może być stosowana do analizy sygnałów chropowatości powierzchni.

EN

In this paper, authors show the research results of analysis of the geometric structure of surface The authors test the possibility of adaptation of wavelet transform to determine the feed per revolution parameter value during face milling process for six kinds of material. Two mother wavelets (Morlet and Mexican hat) had been used to carry out the study. After analyzing the research results authors concluded that continuous wavelet transform may be used to analysis of surface roughness.

15

Frezowanie powierzchnii napawanych laserowo

Wijas M., Nowakowski Ł.

Mechanik

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2015

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R. 88, nr 8-9CD2

320--328

PL

Praca przedstawia wyniki badań eksperymentalnych frezowania powierzchni napawanych laserowo. Jej celem było przeprowadzenie procesu regeneracji płaskiej powierzchni blachy wykonanej ze stali C45 poprzez napawanie laserowe oraz frezowanie czołowe. Ocenę rezultatów procesu regeneracji przeprowadzono na podstawie pomiarów wybranych parametrów struktury geometrycznej powierzchni zregenerowanej.

EN

The study shows the results of experimental tests of milling of laser-hardfaced surfaces. The goal was to carry out a process of regeneration of a flat surface of a C45 steel sheet through laser hardfacing and face milling. The results of the regeneration process were assessed on the basis of measurements of assorted geometrical structure parameters of the regenerated surface.

16

Frezowanie czołowe stali C45 po cięciu laserem narzędziami o ostrzach z regularnego azotku boru

Skoczylas A., Zaleski K.

Mechanik

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2015

|

R. 88, nr 8-9CD2

311--319

PL

Przedstawiono wyniki badań frezowania czołowego – narzędziami o ostrzach z regularnego azotku boru – warstw charakteryzujących się prążkowaną strukturą, powstałych w procesie cięcia wiązką lasera. Poddano analizie składowe siły skrawania występujące podczas frezowania czołowego oraz chropowatość obrobionej powierzchni. W badaniach wykorzystano próbki ze stali C45. Głębokość skrawania była dobierana w takim zakresie, aby usunąć tylko cześć warstwy utwardzonej, która powstała w procesie cięcia wiązką laserową.

EN

The article presents the results of milling layers, characterized with a “stria” structure, formed during laser cutting. The process was conducted with blades made of cubic boron nitride. Surface roughness and components of the cutting force, occurring during face milling were analyzed. The C45 steel samples were used in the study. The depth of cut was selected in such a way as to remove only a part of the layer formed by cutting with a laser beam.

17

Badania porównawcze wybranych wskaźników skrawalności wprocesie frezowania stopów niklu INCONEL 625 i INCONEL 718

Bławucki S., Matuszak J., Zaleski K.

Mechanik

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2015

|

R. 88, nr 8-9CD2

293-301

PL

Stopy niklu są cennym materiałem konstrukcyjnym, stosowanym w przemyśle lotniczym, energetycznym i chemicznym. Wytwarzanie elementów z tych stopów wiąże się z dużymi problemami ze względu na ich trudnoobrabialność. W pracy przedstawiono wyniki badań eksperymentalnych składowych siły skrawania oraz chropowatości powierzchni w procesie frezowania czołowego trudnoobrabialnych stopów niklu INCONEL 625 i INCONEL 718. Badania prowadzono przy zmiennych parametrach technologicznych.

EN

Nickel alloys are valuable constructional materials, used in aircraft, power and chemical industry. These alloys are hard to machine, so production of nickel alloy parts causes some difficulties. This paper presents experimental research results of cutting force, and the surface roughness in face milling of INCONEL 625 and INCONEL 718 nickel alloys, which are difficult to machine. Research was conducted with variable technological parameters.

18

Analiza procesu frezowania stali NC6

Nowakowski Ł., Miko E., Maj P.

Mechanik

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2015

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R. 88, nr 3CD

30--35

PL

W pracy przedstawiono wyniki analizy procesu frezowania czołowego stali NC6 głowicą walcowo-czołową oraz jego wpływ na chropowatość powierzchni. Podczas prób skrawania zmierzono przemieszczenia względne w układzie narzędzie przedmiot obrabiany, wyznaczono wartości minimalnej grubości warstwy skrawanej. Wyznaczony został wpływ posuwu i prędkości skrawania na wartość parametru minimalnej grubości warstwy skrawanej oraz przemieszczeń względnych w układzie narzędzie przedmiot obrabiany.

EN

The paper shown the results of the analysis NC6 steel face milling process using square shoulder mill and its influence on the surface roughness. During the cutting tests the relative displacement in the system toolworkpiece were measured, also the minimum thickness of the cut layer were determined. Was designated the impact of feed rate and cutting speed on the value of the minimum thickness of the cut layer and the relative displacements in the system tool-workpiece.

19

Analiza modelu do prognozowania chropowatości powierzchni frezowanych czołowo ostrzami o ostrym narożu

Nowakowski Ł., Miko E.

Logistyka

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2014

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nr 6

7981--7988

PL

Proces formowania chropowatości powierzchni jest skomplikowany i zależy od wielu czynników. Z analizy najnowszych pozycji literaturowych na ten temat wynika, że nowy uogólniony model do prognozowania chropowatości Ra powierzchni frezowanych czołowo płytkami o ostrym narożu, bierze pod uwagę ilościowe odwzorowanie ostrza, drgania narzędzia w stosunku do obrabianego przedmiotu, bicie ostrzy narzędzia (dla narzędzi wieloostrzowych), a pośrednio także zużycie narzędzia. Model ten może być wykorzystywany do budowy oddzielnych modeli dla większości typowych operacji obróbkowych, których chropowatość powierzchni jest reprezentowana przez parametr Ra. Symulacje przeprowadzone z wykorzystaniem opisanego w pracy modelu umożliwiły opracowanie nomogramów, które mogą być używane do przewidywania i kontroli chropowatości Ra powierzchni frezowanych czołowo.

EN

The process of surface roughness formation is complex and dependent on numerous factors. The analysis of the latest reports on the subject shows that a new generalized mathematical model of roughness formation was developed for surfaces shaped with sharp-nose tools. The model provides us with a quantitative analysis of the effects of the tool representation, tool vibrations in relation to the workpiece, tool runout (for multicutter tools) and, indirectly, also tool wear. This model can be used to prepare separate models for most of the typical machining operations. Surface roughness is represented here by Ra parameter. Simulations carried out for this model helped to develop nomograms which can be used for predicting and controlling the roughness Ra of surfaces sculptured by face milling.

20

Powstawanie zadziorów przy frezowaniu współbieżnym i przeciwbieżnym stopu AlSi10Mg

Falkowicz K., Kuczmaszewski J.

Przegląd Mechaniczny

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2012

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nr 9

23-27

PL

Operacje usuwania zadziorów są dość kosztowne, dlatego też znajomość tworzenia się zadziorów pozwala na uwypuklenie istotności tego zagadnienia w świetle ogólnie rozumianej obróbki skrawaniem. W artykule przedstawiony został? mechanizm formowania si´ zadziorów w procesie frezowania czołowego stopu AlSi10Mg. Zbadano również wpływ poszczególnych parametrów obróbki na wielkość powstających zadziorów.

EN

Since deburring is a costly and non-value-adding operation, the understanding and control of burr formation is a research topic with high relevance to industrial applications. The purpose of this paper was to study the burr formation mechanisms in face milling process of aluminum alloy AlSi10Mg, and to investigate the influence of machining parameters on burr formation in face milling.