Analysis of chip formation and cutting forces in end milling AISI D2 tool steel with different cutting tool geometries

The purpose of this study was to investigate and establish the correlations between milling tool geometry, cutting conditions, as input factors and the cutting forces variations and chips formation, as output factors when end milling of AISI D2 tool steel. The experiments were carried out using a Taguchi design array. The chip shape and microstructure and cutting force components were analyzed. The results of the study show that the cutting tool geometry has a great influence over segmented chip formation mechanism and cutting force levels

Analysis of chip formation and cutting forces in end milling AISI D2 tool steel with different cutting tool geometries

The purpose of this study was to investigate and establish the correlations between milling tool geometry, cutting conditions, as input factors and the cutting forces variations and chips formation, as output factors when end milling of AISI D2 tool steel. The experiments were carried out using a Taguchi design array. The chip shape and microstructure and cutting force components were analyzed. The results of the study show that the cutting tool geometry has a great influence over segmented chip formation mechanism and cutting force levels

Waviness at dry high-speed face milling of some hard steels

Waviness is a parameter used to complete information on the machined surface state. There is little scientific and technical information on the influence exerted by the cutting conditions and the workpiece material hardness on the values of some parameters that define the waviness of milled surface. No works have been identified to present such information for dry high-speed face milling applied to hard steel workpieces. A factorial experiment with four independent variables at three variation levels was planned to model the influence of milling speed, feed, cutting depth, and steel hardness on the total heights of the profile and surface waviness for dry high-speed face milling. Mathematical processing of experimental results was used to identify the power type function and empirical mathematical models. These models highlight the direction of variation and the intensity of influence exerted by the considered input factors on the values of two waviness parameters in the case of dry high-speed face milling of samples made of four hard steels. It has been observed that the increase in steel hardness increases the total heights of the profile and surface waviness. In the case of two types of steel, a good correlation was identified between the values of the total profile waviness height and the total surface waviness height, respectively, using the Pearson correlation coefficient

CHIP DEFORMATION IN HIGH SPEED FACE MILLING OF THE HARD TOOL STEEL X210CR12

High speed machining of hard materials is considered to be an efficient machining technology for die and mold industry. The paper proposes an investigation on the deformation of chips generated in high speed machining of tool steel X210Cr12. An experimental research was designed and materialized, by taking into consideration a face milling process. A power type function empirical mathematical model was established in order to highlight the influence exerted by the steel hardness, milling speed, feed rate and depth of cut on the chips apparent density. Graphical representations confirmed the increase of the apparent density when the steel hardness and milling speed increase, while the increase of the feed rate and depth of cut determine a decrease of the chips apparent density

Tool electrode wear in electrical discharge of small diameter holes

In the paper, the problem of obtaining small diameter holes in workpieces made of high speed steel by electrical discharge machining was formulated. A fulfil factorial experiment was designed and materialized, taking into consideration the tool electrode diameter, pulse on time and pulse off time as independent variables. The tool electrode wear was evaluated by means of the decrease of tool electrode mass and length. On the base of experimental results, power type empirical mathematical models were determined. One noticed the higher influence exerted by the too electrode diameter, whose increase determine the decrease of the tool electrode

Tool electrode wear in electrical discharge of small diameter holes

In the paper, the problem of obtaining small diameter holes in workpieces made of high speed steel by electrical discharge machining was formulated. A fulfil factorial experiment was designed and materialized, taking into consideration the tool electrode diameter, pulse on time and pulse off time as independent variables. The tool electrode wear was evaluated by means of the decrease of tool electrode mass and length. On the base of experimental results, power type empirical mathematical models were determined. One noticed the higher influence exerted by the too electrode diameter, whose increase determine the decrease of the tool electrode

Tool electrode wear in electrical discharge of small diameter holes

In the paper, the problem of obtaining small diameter holes in workpieces made of high speed steel by electrical discharge machining was formulated. A fulfil factorial experiment was designed and materialized, taking into consideration the tool electrode diameter, pulse on time and pulse off time as independent variables. The tool electrode wear was evaluated by means of the decrease of tool electrode mass and length. On the base of experimental results, power type empirical mathematical models were determined. One noticed the higher influence exerted by the too electrode diameter, whose increase determine the decrease of the tool electrode

Theoretical considerations concerning the profile error of the thread flank

In the case of metric thread, a possible source of the flank error could be the position of the cutting tool edge, which could not intersect the circular cylindrical surface axis. An analytical method of approximation was applied to model the way in which the flank error is generated by considering some geometrical conditions. A theoretical simplified model was determined to highlight the influence of the thread external diameter and of the distance between the circular cylindrical surface axis and the thread rectilinear generatrix on the profile error of thread flank

Selection of a Solution When Using Axiomatic Design

Over the years, the importance of the creativity inclusively in the field of design activities was highlighted. In accordance with the opinions of certain researchers, the divergent thinking could contribute to the increase of creative processes efficiency. On the other hand, the axiomatic design method is considered as a method able to stimulate the technical creativity when the problem of designing a mechanical equipment is stated. To increase the efficiency of using the axiomatic design method, the possibility of selecting the most convenient solution among many available solutions could be discussed. The analysis revealed that there are many methods that could be applied in the process of optimum solution selection among many available solutions. In this paper, some aspects concerning the possibilities of using the method of analytic hierarchy process are analyzed, inclusively by considering a case study concerning a device for investigating the universal horizontal lathe rigidity. Afterwards, the first axiom from axiomatic design method was applied to define the selected solution for the approached device

Theoretical considerations concerning the profile error of the thread flank

In the case of metric thread, a possible source of the flank error could be the position of the cutting tool edge, which could not intersect the circular cylindrical surface axis. An analytical method of approximation was applied to model the way in which the flank error is generated by considering some geometrical conditions. A theoretical simplified model was determined to highlight the influence of the thread external diameter and of the distance between the circular cylindrical surface axis and the thread rectilinear generatrix on the profile error of thread flank