Relationship of chip load and spindle speed on cutting force and surface integrity for high-speed dry end-milling Hastelloy X material
The effect of the cutting force during high-speed machining (HSM) has been extensively focused on by many researchers and the existing literature mainly discuss the approaches that can be taken to reduce the cutting force when machining nickel-based superalloys, such as by reducing the chip load...
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| Format: | Thesis |
| Language: | English |
| Published: |
2019
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| Subjects: | |
| Online Access: | http://psasir.upm.edu.my/id/eprint/85497/1/FK%202020%2032%20ir.pdf |
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| Summary: | The effect of the cutting force during high-speed machining (HSM) has been
extensively focused on by many researchers and the existing literature mainly
discuss the approaches that can be taken to reduce the cutting force when machining
nickel-based superalloys, such as by reducing the chip load while increasing the
spindle speed. Increasing the spindle speed can increase the cutting speed, which
indirectly reduces the cutting force. While, a reduction in the chip load decreases the
cutting force needed to remove the unwanted material. On the other hand, a decrease
in chip load results in low material removal rate (MRR). Therefore, it is contrary to
the principle of HSM, where increasing the spindle speed while reducing the chip
load only reduce the cutting force, rather than reducing the cutting force and
increasing the MRR. Furthermore, it has been proven that the surface integrity after
machining directly affects the reliability and life of the product. Although the
ultimate research goal of the cutting force is to improve cost-effectiveness and
productivity, it is also crucial to maintain or improve the surface integrity of a
product. Therefore, the main aim of this research is to study the influence of
increases in spindle speed at constant chip load on the cutting force and surface
integrity of high-speed end-milling of Hastelloy X material under dry conditions.
The cutting force behaviour was simulated by using AdvantEdge, while
dynamometer was used to measure the cutting force under experimental tests. The
research then analysed the surface integrity of Hastelloy X. Surface integrity, that
included surface roughness, surface hardness and sub-surface residual stress, was
observed with the purpose of correlating it with the optimum combination of chip
load and spindle speed under experimental conditions, and also the behaviour of
cutting force components and resultant force. Results of the experimental tests
revealed that the cutting force components and resultant force had quadratic
behaviour. In addition, axial force was the dominant factor affecting the resultant
force, followed by the normal force and feed force. In terms of surface integrity, the surface roughness and sub-surface residual stress were in line with the behaviour of
the cutting force components and resultant force. However, the behaviour of surface
hardness did not necessarily correspond to the behaviour of the cutting force
components and resultant force when the spindle speed was increased at a constant
chip load. Finally, the ideal combination of chip load and spindle speed in order for
the manufacturing industry to obtain the ideal cutting force, MRR and surface
integrity during high-speed end-milling of Hastelloy X under dry conditions at 0.2
mm depth of cut was proposed at 0.016 mm/tooth and 21,400 rpm in half-immersion
down-milling, 0.019 mm/tooth and 23,920 rpm in half-immersion up-milling, 0.016
mm/tooth and 23,560 rpm in full-immersion down-milling, and 0.016 mm/tooth and
24,640 rpm in full-immersion up-milling. |
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