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Metal Cutting Principles

The torsional angle, χYDeg, of a machine tool-device-spindle unit is formulated in a face-milling operation. As there is no angular compliance in the technical specifications for the machine tool, a novel method is proposed for the determination of the angular compliance values of a GF2171S5 machine milling system. Deviation from flatness, ΔZfl, is therefore also modeled in this paper, for the first time, by considering the parameters of milling and tool wear. The proposed model performs an acceptable evaluation of various types of flatness deviation for different flank wear values. The face milling and tool-wear parameters and their influence on the torsional angle of the tool-device-spindle unit are calculated. Besides, the effects of different settings on the machining process and the material-cutting speed vc and depth ap, cutting-edge angles kr, and tool slenderness-lo/D in combination with various depths of flank wear VB on the torsional angle of the mill χYDeg and flatness deviation ΔZfl are investigated. This method of determining the angular torsional values can be applied to other milling machines. Moreover, the model can be used to compensate the torsional angle of the mill face, thereby minimizing the flatness deviation.

Modeling flatness deviation in face milling considering angular movement of the machine tool system components and tool flank wear

The aim of the work is find out influence of feed rate on the quality for the machined surface, especially surface roughness. The experiment was carried out by cutting tool HURCO VMXt30 with respect to the following cutting parameter: cutting speed 250; 350; 450; 550 and 850 m.min-1, feed 0,1; 0,5 and 1,0 mm/tooth. For testing was used two most common materials in the steel grade 1.1191 (12 050) and 1.2343 (19 552), and we chose two ordinary parameters of surface roughness; Ra - arithmetical mean roughness deviation and Rz - the largest inequalities height profile in the transverse direction and the longitudinal direction of machining. The structural equations will be the result which can describe the character depending on the cut surface parameters.

Surface Roughness after Machining and Influence of Feed Rate on Process

Optimization of end milling parameters and determination of the effects of edge profile for high surface quality of AISI H13 steel by using precise and fast measurements

Combination of high feed turning with cryogenic cooling on Haynes 263 and Inconel 718 superalloys

Modern machining processes continuously face cost pressures and high quality expectations. To remain competitive a company must continually identify cost reduction opportunities in production, exploit economic opportunities, and continuously improve production processes. A key technology that represents cost saving opportunities related to cooling lubrication, and simultaneously improves the overall performance of cutting operations, is dry machining. The elimination of coolants or significant reduction in cooling lubricants affects all components of a production system. A detailed analysis and adaptation of cutting parameters, cutting tools, machine tools and the production environment is mandatory to ensure an efficient process and successfully enable dry machining. Case study is shown for examination of cylindricity error and surface roughness of helical milling machined surfaces by environmentally conscious way.

Effect of Environmentally Conscious Machining on Machined Surface Quality

Air gauges as a part of the dimensional inspection systems

. The development of metal machining processes and procedures has been characterized by aiming at accuracy and economy for decades. The applied coolants and lubricants helped this process; however, they are polluting the environment. For today that is a social demand and technical possibility that environmental aspects should predominate better in production engineering. In the frame of this article, through the application of dry hard turning we shall spotlight on its economy and efficiency. We shall prove that, keeping the same accuracy and economic efficiency, it is possible to choose a machining process by which the environmental load can be reduced compared to the most frequently applied grinding.

Possibility of Reducing Environmental Load in Hard Machining

The machining of hardened surfaces can be done even fulfilling the ever stricter accuracy and quality prescriptions, besides the economic efficiency. Decisively, hard machining is highlightedly important in finish processes because the components must meet increased functional demands. Therefore the number and/or the hardness of the hard surfaces on the components is continuously increasing. In practice the demand for such components is high since they are more wear resistant and their tool life may be higher. Today there are several possibilities for finish machining of components having hard surfaces. We have done experiments for hard machining of inner cylindrical surfaces. The examined procedures were as follows: grinding, hard turning, combined machining. The first two procedures (hard turning, grinding) have got different procedure-specific advantages and disadvantages. Combining these two procedures, using-up the advantages of them, the efficiency of the production can be increased. This paper outlines these procedures of hard machining, their applicability, the increase of their efficiency, and the possibilities provided by the combination of the procedures.

Gyula Varga

Papers

Effect of Environmentally Conscious Machining on Machined Surface Quality

Air gauges as a part of the dimensional inspection systems

Possibility of Reducing Environmental Load in Hard Machining

Some Aspects of the Hard Machining of Bore Holes

Determination of specific cutting force components and exponents when applying high feed rates