Modares Mechanical Engineering

Modares Mechanical Engineering

The Effect Of Machining Strategies On The Surface Roughness And Milling Time Of Part With Convex, Concave, And Smooth Surfaces

Document Type : Original Research

Authors
Aeronautical University of Science and Technology
Abstract
The milling process is widely used in the manufacturing industry to shape complex geometric parts. Considering the flexibility of the cutting process and the various variables involved, process optimization has become a key issue in achieving higher productivity and quality. To optimize the process planning, it is important to choose a suitable machining strategy. Implementation and selection of tool path strategies and orientations are very important in the machining process, especially in the aerospace and molding industries. The right choice can lead to significant savings in machining time, improvement of work-piece surface quality, and improvement in tool life, thus leading to overall cost reduction and higher productivity. Therefore, this article aims to identify the best strategy in terms of surface roughness and milling time. In this article, Shallow's strategy has been investigated, and the milling of its finishing stage has been studied and compared with three strategies of the milling process, including raster, 3D offset, and raster flat. In this article, the comparison of the strategies in the Powermill software and with the flat-head finger mill, which can grind the floor and the wall simultaneously, has been done. Tool-cutting parameters were considered constant for all tested strategies. Machining quality was evaluated by comparing surface roughness, surface Topography, and dimension control parameters. The results indicate that the Shallow machining strategy has the lowest surface roughness and the best surface quality, and the raster strategy has the highest surface roughness and the worst surface quality in this test.
Keywords

Subjects


[1] Brown & Sharpe Manufacturing Company (Providence, RI). Practical Treatise on Milling and Milling Machines. Brown & Sharpe Manufacturing Company; 1914.
[2] Kim BH, Chu CN. Effect of cutter mark on surface roughness and scallop height in sculptured surface machining. Computer-Aided Design. 1994 Mar 1;26(3):179-88. https://doi.org/10.1016/0010-4485(94)90041-8
[3] Vickers GW, Quan KW. Ball-mills versus end-mills for curved surface machining. https://doi.org/10.1115/1.3188728
[4] Andrew Warkentin "A multi point machining of sculptured surfaces" A thesis presented to the University of Waterloo in filfilment of the thesis requirement for the degree of Doctor of Philosophy in Mechanical Engineering Waterloo, Ontario, Canada, 1997 Q Andrew Warkentin, 1997.
[5] Ramos AM, Relvas C, Simoes JA. The influence of finishing milling strategies on texture, roughness and dimensional deviations on the machining of complex surfaces. Journal of Materials Processing Technology. 2003 May 10;136(1-3):209-16. https://doi.org/10.1016/S0924-0136(03)00160-2
[6] Toh CK. A study of the effects of cutter path strategies and orientations in milling. Journal of materials processing technology. 2004 Oct 30;152(3):346-56. https://doi.org/10.1016/j.jmatprotec.2004.04.382
[7] Toh CK. Cutter path orientations when high-speed finish milling inclined hardened steel. The International Journal of Advanced Manufacturing Technology. 2006 Jan;27:473-80. https://doi.org/10.1007/s00170-004-2206-4
[8] Mali RA, Aiswaresh R, Gupta TV. The influence of tool-path strategies and cutting parameters on cutting forces, tool wear and surface quality in finish milling of Aluminium 7075 curved surface. The International Journal of Advanced Manufacturing Technology. 2020 May;108:589-601. https://doi.org/10.1007/s00170-020-05414-7
[9] Shajari S, Sadeghi MH, Hassanpour H. The influence of tool path strategies on cutting force and surface texture during ball end milling of low curvature convex surfaces. The Scientific World Journal. 2014 Jan 1;2014. https://doi.org/10.1155/2014/374526
[10] Varga J, Spišák E, Gajdoš I, Mulidrán P. Comparison of milling strategies in the production of shaped surfaces. Adv. Sci. Technol. Res. J. 2022 Dec 1;16:267-74. https://doi.org/10.12913/22998624/156817
[11] Rasti A, Hassanpour H, Sadeghi MH, Sabbaghi Farshi S. Investigation of surface roughness in high speed milling of titanium alloy. Modares Mechanical Engineering. 2016 Feb 10;15(13):82-5. [In Persian]
[12] Mane S, Kumar S. Analysis of surface roughness during turning of AISI 52100 hardened alloy steel using minimal cutting fluid application. Advances in Materials and Processing Technologies. 2022 Aug 31;8(sup1):138-49. https://doi.org/10.1080/2374068X.2020.1855965
[13] Hassanpour H, Sadeghi MH. Effect of cutting fluid application on surface roughness in hard milling of 4340-alloyed steel. Modares Mechanical Engineering. 2015 Mar 10;14(14):50-60. URL: http://mme.modares.ac.ir/article-15-4201-en.html[In Persian]
[14] Bagci E, Yüncüoğlu EU. The Effects of Milling Strategies on Forces, Material Removal Rate, Tool Deflection, and Surface Errors for the Rough Machining of Complex Surfaces. Journal of Mechanical Engineering/Strojniški Vestnik. 2017 Nov 1;63(11). DOI:10.5545/sv-jme.2017.4450.
[15] Uzun M, Usca ÜA, Kuntoğlu M, Gupta MK. Influence of tool path strategies on machining time, tool wear, and surface roughness during milling of AISI X210Cr12 steel. The International Journal of Advanced Manufacturing Technology. 2022 Mar;119(3):2709-20. https://doi.org/10.1007/s00170-021-08365-9
[16] Mohammadi H, Eskandari H, Danaee I. Investigation the Milling Strategies Effects on Machining of Convex Surfaces made of Glass/Epoxy Composite. Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering.;10(1):759-70. [In Persian]
[17] Abbas AT, Abdelnasser E, Naeim N, Alqosaibi KF, Al-Bahkali EA, Elkaseer A. Effect of Milling Strategy on the Surface Quality of AISI P20 Mold Steel. Metals. 2023 Dec 29;14(1):48. https://doi.org/10.3390/met14010048
[18] Elhendawy GA, El-Taybany Y. Evaluation of different milling strategies on the performance of aluminium thin-walled parts. International Journal of Machining and Machinability of Materials. 2024;26(1):85-96. https://doi.org/10.1504/IJMMM.2024.137425
[19] Beșliu-Băncescu I, Tamașag I, Slătineanu L. The influence of the machining strategy on milling of polyetheretherketone (PEEK). The International Journal of Advanced Manufacturing Technology. 2024 Apr 4:1-3. https://doi.org/10.1007/s00170-024-13544-5
[20] Moghadasi AH, Hadad MJ, Kazemi Nasrabadi M. Experimental Study on surface roughness and quality of Hybrid MQL and Thermally-Enhanced Turning of Stainless Steel 17-4 PH (AISI 630). Iranian Journal of Manufacturing Engineering. 2020 Jan 21;6(8):21-32. [In Persian]
[21] Siahvashi, A., Shahbazi, M., Niknam, S. A. The use of neuro-fuzzy network coupled with meta-heuristic learning methods to predict surface roughness in the machining of aluminum alloys. Iranian Journal of Manufacturing Engineering, 2024; (): -. doi: 10.22034/ijme.2024.412021.1816. [In Persian]
[22] Bagheri A, Abedini V, Hajialimohammadi A. Experimental Investigation of the Effective Parameters in 7075-T6 Aluminum Machining Process on Surface Roughness Using Minimum Quantity Lubrication (MQL) and Cold Fluid. Iranian Journal of Manufacturing Engineering. 2021 Aug 23;8(6):7-14. [In Persian]
[23] Power mill Manual, Delcam, 2010.
[24] Shajari SH, Sadeghi M.H, Hasanpour H, Khoran M. Experimental investigation of the effect of milling strategies on time and roughness of curved surfaces. The 12th Conference of Manufacturing and Production Engineering of Iran. 2011. [In Persian]
[25] Shajari SH, Sadeghi M.H. Investigating the effect of various milling strategies in machining a sample of convex surfaces made of stainless steel. Dissertation of Tarbiat Modares University - Technical Faculty. 2011. [In Persian]