High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude
High feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the...
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| Format: | Article |
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MDPI AG
2021-04-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/14/9/2196 |
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| author | Marcin Płodzień Łukasz Żyłka Paweł Sułkowicz Krzysztof Żak Szymon Wojciechowski |
| author_facet | Marcin Płodzień Łukasz Żyłka Paweł Sułkowicz Krzysztof Żak Szymon Wojciechowski |
| author_sort | Marcin Płodzień |
| collection | DOAJ |
| description | High feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the high feed milling (HFM), experimental tests were conducted, preceded by an analysis of cutting zones when milling with an HF face cutter. The face milling tests of 42CrMo4 steel with the use of an HF cutter characterized by an entering angle, dependent on axial depth of cut <i>a<sub>p</sub></i> and insert radius <i>r</i> values, as well as with a conventional face cutter with the entering angle of 45° were performed. The study focused on analyzing the vibration amplitude, cutting force components in the workpiece coordinate system, and surface roughness. The experimental tests proved, that when milling with constant cut layer thickness, the high feed cutter allowed to obtain twice the cutting volume in comparison with the conventional face cutter. However, higher machining efficiency resulted in an increase in cutting force components. Furthermore, the results indicate significantly higher surface roughness and higher vibration amplitudes when milling with the HF cutter. |
| first_indexed | 2024-03-10T11:59:35Z |
| format | Article |
| id | doaj.art-15f981b6655c492f8eedb6bfa5c12f03 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T11:59:35Z |
| publishDate | 2021-04-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-15f981b6655c492f8eedb6bfa5c12f032023-11-21T17:02:43ZengMDPI AGMaterials1996-19442021-04-01149219610.3390/ma14092196High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration AmplitudeMarcin Płodzień0Łukasz Żyłka1Paweł Sułkowicz2Krzysztof Żak3Szymon Wojciechowski4Department of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, ul. W. Pola 2, 35-959 Rzeszow, PolandDepartment of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, ul. W. Pola 2, 35-959 Rzeszow, PolandDepartment of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, ul. W. Pola 2, 35-959 Rzeszow, PolandDepartment of Manufacturing and Materials Engineering, The Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758 Opole, PolandInstitute of Mechanical Technology, The Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, PolandHigh feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the high feed milling (HFM), experimental tests were conducted, preceded by an analysis of cutting zones when milling with an HF face cutter. The face milling tests of 42CrMo4 steel with the use of an HF cutter characterized by an entering angle, dependent on axial depth of cut <i>a<sub>p</sub></i> and insert radius <i>r</i> values, as well as with a conventional face cutter with the entering angle of 45° were performed. The study focused on analyzing the vibration amplitude, cutting force components in the workpiece coordinate system, and surface roughness. The experimental tests proved, that when milling with constant cut layer thickness, the high feed cutter allowed to obtain twice the cutting volume in comparison with the conventional face cutter. However, higher machining efficiency resulted in an increase in cutting force components. Furthermore, the results indicate significantly higher surface roughness and higher vibration amplitudes when milling with the HF cutter.https://www.mdpi.com/1996-1944/14/9/2196high feed millingface millingcutting forcevibration |
| spellingShingle | Marcin Płodzień Łukasz Żyłka Paweł Sułkowicz Krzysztof Żak Szymon Wojciechowski High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude Materials high feed milling face milling cutting force vibration |
| title | High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude |
| title_full | High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude |
| title_fullStr | High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude |
| title_full_unstemmed | High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude |
| title_short | High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude |
| title_sort | high performance face milling of 42crmo4 steel influence of entering angle on the measured surface roughness cutting force and vibration amplitude |
| topic | high feed milling face milling cutting force vibration |
| url | https://www.mdpi.com/1996-1944/14/9/2196 |
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