Analysis on high-speed face-milling of 7075-T6 aluminum using carbide and diamond cutters

This research is concerned with the analytical and experimental study on the high-speed face milling of 7075-T6 aluminum alloys with a single insert fly-cutter. The results are analyzed in terms of cutting forces, chip morphology, and surface integrity of the workpiece machined with carbide and diamond inserts. It is shown that a high cutting speed leads to a high chip flow angle, very low thrust forces and a high shear angle, while producing a thinner chip. Chip morphology studies indicate that shear localization can occur at higher feeds even for 7075-T6, which is known to produce continuous chips. The resultant compressive residual stresses are shown for the variation of cutting parameters and cutting tool material. The analysis of the high-speed cutting process mechanics is presented, based on the calculation results using extended oblique machining theory and finite element simulation.

[1]  Herbert Schulz,et al.  High-Speed Machining , 1992 .

[2]  D. G. Flom,et al.  Highlights of the DARPA Advanced Machining Research Program , 1985 .

[3]  P. Mathew,et al.  Predicting the Effects of Very High Cutting Speeds on Cutting Forces, etc. , 1982 .

[4]  A. Moufki,et al.  Thermoviscoplastic modelling of oblique cutting: forces and chip flow predictions , 2000 .

[5]  E. Armarego,et al.  The Machining of Metals , 1969 .

[6]  M. C. Shaw,et al.  Tool Face Temperatures in High Speed Milling , 1990 .

[7]  J. Hodowany,et al.  MODELING THE PHYSICS OF METAL CUTTING IN HIGH-SPEED MACHINING , 1998 .

[8]  Jeong-Du Kim,et al.  High-spend machining of aluminium using diamond endmills , 1997 .

[9]  Yung C. Shin,et al.  A new procedure to determine instantaneous cutting force coefficients for machining force prediction , 1997 .

[10]  A. Boyle,et al.  Computer aided cutting process parameter selection for high speed milling , 1996 .

[11]  Hossam A. Kishawy,et al.  Surface Integrity of Die Material in High Speed Hard Machining, Part 2: Microhardness Variations and Residual Stresses , 2000 .

[12]  A. A. Radwan.  Investigation of secondary deformation zone and mean coefficient of friction during the machining of 5083-H34 aluminum alloy , 1985 .

[13]  松尾 哲夫.  The Machining of Metals, E.J.A.Armarego & R.H.Brown, Prentice-Hall, Inc., 1969 , 1984 .

[14]  M. C. Shaw,et al.  Mechanics of Saw-Tooth Chip Formation in Metal Cutting , 1999 .

[15]  P. Oxley,et al.  Mechanics of Orthogonal Machining: Allowing for the Effects of Strain Rate and Temperature on Tool-Chip Friction , 1968 .

[16]  E. Usui,et al.  Analytical Prediction of Three Dimensional Cutting Process—Part 2: Chip Formation and Cutting Force with Conventional Single-Point Tool , 1978 .

[17]  W. König,et al.  Residual Stresses — Measurement and Causes in Machining Processes , 1982 .