High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude
Abstract
:1. Introduction
2. Materials and Methods
- universal face cutter MFA145-063R04A22-SE13 (ENGRAM)—entering angle κr = 45°,
- High-Feed face cutter MKB113-063R04A22-SD12 (ENGRAM)—entering angle κr = 21.3°.
3. Results and Discussion
3.1. The Analysis of Cutting Force Components in HF and Conventional Face Milling
3.2. Analysis of the Vibration Amplitude Components during HF and Conventional Face Milling
3.3. Analysis of the Surface Roughness after HF and Conventional Face Milling
4. Conclusions
- using the HF cutter, it is possible to achieve over twice the cutting volumes obtained during milling with the use of a conventional face cutter with the entering angle of κr = 45°, with constant cut layer thickness hmax;
- during milling with the HF cutter, higher values of the cutting force components occur, eight times the increase in the value of the axial cutting force component Fa, four times the increase in the feed cutting force component Ff, and two times the increase in the normal to feed component FfN were recorded;
- despite the different shape of the cut layer cross-section during milling with the HF cutter, specific values of the cutting force in relation to the cut layer cross-section are similar for both tool;
- taking into consideration the distribution and values of the cutting force components (mainly high values of the axial component, exerting load on spindle’s bearings) as well as vibration amplitude values, it can be concluded, that the HF milling process should take place on stiff machine tools, of which the design enables transferring high loads in the direction of a spindle’s axis;
- milling with the use of the HF cutter in most cases contributes to occurring higher vibration amplitudes, compared with milling with the face cutter with the entering angle of κr = 45°, which results from different values of cut layer thickness in cross-sectional area;
- the reason for the higher level of vibrations is the chip forming process as well as the shape and size of a cut layer during milling with the HF cutter, where cut layer thickness h varies with the depth of cut and where there is an area below hmin, where elastic-plastic deformation of the material is increased and the tool is deflected;
- the average vibration RMS values in the feed and normal-to-feed directions for up milling with the HF cutter are equal to or even lower than for the conventional cutter. It means that in some machining conditions, milling with the HF cutter presents an alternative for the conventional cutter, with significantly higher machining efficiency and similar machining loads;
- the use of the HF cutter causes significantly higher surface roughness, in comparison with the conventional face cutter with the entering angle of κr = 45°, due to the variation in cut layer cross-sectional thickness and increase in plastic deformation of the material;
- the increase in cut layer thickness during HF milling results in reducing the surface roughness, which can be explained by the reduction of the elastic-plastic area in the cut layer below the value of the minimal cut layer hmin.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
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Chip thickness hmax, mm | 0.085 | 0.13 | 0.17 | 0.21 | Type of mill cutter |
Cross section area Scmax, mm2 | 0.12 | 0.18 | 0.24 | 0.3 | Face mill |
0.24 | 0.35 | 0.45 | 0.55 | HF face mill | |
Feed per tooth fz, mm/tooth | 0.14 | 0.21 | 0.28 | 0.35 | Face mill |
0.28 | 0.42 | 0.55 | 0.68 | HF face mill | |
Cutting efficiency Qw, mm3/min | 6417 | 9815 | 12835 | 15855 | Face mill |
12,472 | 19,106 | 24,958 | 30,854 | HF face mill |
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Płodzień, M.; Żyłka, Ł.; Sułkowicz, P.; Żak, K.; Wojciechowski, S. High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude. Materials 2021, 14, 2196. https://doi.org/10.3390/ma14092196
Płodzień M, Żyłka Ł, Sułkowicz P, Żak K, Wojciechowski S. High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude. Materials. 2021; 14(9):2196. https://doi.org/10.3390/ma14092196
Chicago/Turabian StylePłodzień, Marcin, Łukasz Żyłka, Paweł Sułkowicz, Krzysztof Żak, and Szymon Wojciechowski. 2021. "High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude" Materials 14, no. 9: 2196. https://doi.org/10.3390/ma14092196