Geometrical analysis of thread milling – Part 1: Evaluation of tool angles

Thread milling is a method which is increasingly used for machining thread. For this operation, a helical interpolation is required. Furthermore, the thread mill is a tool whose geometry is rather complex. Its envelope profile is linked to the thread profile and a single tooth of the thread mill is composed of three continuous cutting edges. The present study proposes a geometrical model and an analytical formulation to define the rake face and the cutting edge. Further, the calculations of cutting planes and cutting angles are explained. The analysis shows specific aspects of thread mills, in particular the fact that the flute angle may lead to a negative rake angle. This study is a contribution to cutting geometry aspect and constitutes a step for cutting force model in thread milling

Welding in solid state

The importance of the Solid State Processes (SSP) has increased in the last decade due to the industry demands of improved properties of joined/surfaced materials, combined with cost reduction and energy saving. New and/or micro-scale solid state processed materials are used by aerospace, automotive and electrotechnics industry. Nowadays, classic SSP are mainly applied to light materials, but progresses were also reported in steels. In this field, the tools design, the technology and practical techniques surpassed the fundamental approach of the materials solid state processing. The SSP parameters evaluation is based on different experiments, approaching the material flow in the large plastic deformation domain. The paper approaches the solid state welding/joining and surface processing. The envisaged SSP are solid state joining processes as Cold Welding (butt and spot welding), Friction Stir Welding – FSW, and surface processing, Friction Stir Processing - FSP. Therefore, the investigation targeted the deformation and flow pattern of the parent metal in case of cold welding and FSW/FSP, processes parameters evaluation and correlation, local analysis of the material structural transformations, and material hardening

Analysis and modeling of green wood milling: Chip production by slabber

During the primary transformation of wood, logs are faced with slabber heads. Chips produced are raw materials for pulp paper and particleboard industries. Efficiency of these industries is partly due to particle size distribution. Command of this distribution is no easy matter because of great dependence on cutting conditions and variability in material. This study aimed a better understanding and predictionof chip fragmentation. It starts with a detailed description of cutting kinematic and interaction between knife and log. This leads to the numerical development of a generic slabber head. Chip fragmentation phenomena were studied through experiments in dynamic conditions. These experiments were carried out thanks to a pendulum (Vc = 400 m/min). It was instrumented with piezoelectric force sensors and high speed camera. Obtained results agreed very well with previous quasi-static experiments

Machining and grinding of ultrahigh-strength steels and stainless steel alloys

Machining and grinding of ultrahigh-strength steels and stainless steel alloy

Analytical prediction of stability limit in turning operations

Unstable cutting due to chatter vibrations is one of the most important problems during metal cutting operations. Chatter can be a limitation for productivity and surface quality in turning operations, especially when long and slender tools and parts are involved. In this study, an analytical stability method for turning process is presented. The model takes the cutting geometry into consideration, and proposes a new solution procedure for the dynamic chip thickness at the insert nose. The analytically calculated absolute stable depth of cuts are compared with the chatter test results, and a good agreement is observed

Investigation of tool geometry effect and penetration strategies on cutting forces during thread milling

The application of thread milling is increasing in industry because of its inherent advantages over other thread cutting techniques. The objective of this study is to investigate the effect of milling cutter tool geometry on cutting forces during thread milling. The proposed method can compare the performance of milling cutters in spite of the different number of tooth. The best thread milling cutter among the studied tools was determined from the cutting forces point of view. Furthermore, this study also pinpoints the best penetration strategy that provides minimum cutting forces. Lower cutting force variations will lead to fewer vibrations of the tool which in turn will produce accurate part.Postdoc de V Sharma financé par la région Bourgogn

Analytical stability models for turning and boring operations

In this paper an analytical model for stability limit predictions in turning and boring operations is proposed. The multi-dimensional model includes the 3D geometry of the processes. In addition a model for the chip thickness at the insert nose radius is also proposed to observe the effect of the insert nose radius on the chatter stability limit. Chatter experiments are conducted for both turning and boring in order to compare with analytical results and good agreement is observed

Effects of cutting angle, edge preparation, and nano-structured coating on milling performance of a gamma titanium aluminide

Gamma titanium aluminides are intermetallic alloys. Recently, they have been evaluated as important contenders for structural applications in the automotive and aerospace sectors. This is due to their excellent high-temperature performances and their significantly lower density compared to Nickel-based superalloys. In this paper, an analysis of machinability of a gamma TiAl obtained via an electron beam melting (EBM) process is presented. The effects of tool geometry modifications, in terms of cutting tool angles and cutting edge preparation, were investigated. The reduction of radial rake angle and the drag finishing process for cutting edge preparation resulted in an increase of the tool life of the carbide end mills. Nanogradient tool coatings were also observed to affect tool wear during milling tests, and the results highlight that AlSiTiN coating performs better compared to CrAlSiN coating. A post-coating polishing treatment was also taken into account, and it allowed a further reduction of tool wear. The overall results indicate that the machinability of this difficult-to-cut material can be significantly improved by an adjustment of the cutting edge geometry, and by using an AlSiTiN coating syste

Analytical modeling of chatter stability in turning and boring operations: a multi-dimensional approach

In this study, an analytical model for the stability of turning and boring processes is proposed. The proposed model is a step ahead from the previous studies as it includes the dynamics of the system in a multidimensional form, uses the true process geometry and models the insert nose radius in a precise manner. Simulations are conducted in order to compare the results with the traditional oriented transfer function stability model, and to show the effects of the insert nose radius on the stability limit. It is shown that very high errors in stability limit predictions can be caused when the true process geometry is not considered in the calculations. The proposed stability model predictions are compared with experimental results and an acceptable agreement is observed

Analytical models for high performance milling. Part I: cutting forces, structural deformations and tolerance integrity

Milling is one of the most common manufacturing processes in industry. Despite recent advances in machining technology, productivity in milling is usually reduced due to the process limitations such as high cutting forces and stability. If milling conditions are not selected properly, the process may result in violations of machine limitations and part quality, or reduced productivity. The usual practice in machining operations is to use experience-based selection of cutting parameters which may not yield optimum conditions. In this two-part paper, milling force, part and tool deection, form error and stability models are presented. These methods can be used to check the process constraints as well as optimal selection of the cutting conditions for high performance milling. The use of the models in optimizing the process variables such as feed, depth of cut and spindle speed are demonstrated by simulations and experiments