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TECHNICAL PAPERS

The Effect of Preheating of Work Material on Chatter During End Milling of Medium Carbon Steel Performed on a Vertical Machining Center (VMC)

[+] Author and Article Information
A. K. M. N. Amin, M. Abdelgadir

Department of Mechanical Engineering, Faculty of Engineering, International Islamic University Malaysia, Jalan Gombak, 53100 Kuala Lumpur, Malaysia

J. Manuf. Sci. Eng 125(4), 674-680 (Nov 11, 2003) (7 pages) doi:10.1115/1.1596557 History: Received March 01, 2003; Online November 11, 2003
Copyright © 2003 by ASME
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References

Trent, E. M., 2000, Metal Cutting, Oxford Limited, London.
Talantov, N. V., Amin, A. K. M. N., and Chereomushnikov, N. P., 1980, “Temperature Deformation Laws of Chatter Formation During Metal Cutting Process,” The 5th Soviet National Conference “Teplophysika Technologichieskikh Processov,” Volgograd (USSR), 92p.
Amin,  A. K. M. N., 1983, “Investigation of the Mechanism of Chatter Formation During Metal Cutting Process,” Mech. Engg. Res. Bulletin, 6(1), BUET., Dhaka, pp. 11–18.
Amin,  A. K. M. N., 1985, “Influence of the Characteristics of Machine-Tool-Fixture-Work (MTFW) System on Chatter,” Journal of the Institute of Engineers, Bangladesh (IEB), 13(4), Dhaka, pp. 9–16.
Amin,  A. K. M. N., and Talantov,  N. V., 1987, “Investigation of the Influence of Chatter on Tool Wear,” Mechanical Engineering Research Bulletin, BUET, 9(1), Dhaka, pp. 11–18.
Kim and Kiho, 1994, “Influence of Process Parameters on Change in Dynamic Behavior of the Work Piece in Lathe Turning,” Iowa State University, Technical digest, MR94137, 7P, 2nd Quarter.
Nachtigal, et al., 1976, “Apparatus for Controlling Vibrational Chatter in a Machine-Tool Utilizing an Updated Synthesis Circuit,” United States Patent No. 3967515, United States.
Delio, 1992, “Method of Controlling Chatter in a Machine Tool,” United States Patent No. 517358, United States.
Amin,  A. K. M. N., and Talantov,  N. V., 1986, “Influence of the Instability of Chip Formation and Preheating of Work on Tool Life in Machining High Temperature Resistant Steel and Titanium Alloys,” Mechanical Eng. Res. Bull. 9(1), pp. 52–62.
Israd, H. J., 2002, “Investigation of Machine Tool Chatter in an End Milling Operation on a Vertical Machining Center,” Master Thesis, IIUM, Malaysia, 156 p.

Figures

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Block diagram of the experimental setup
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Natural frequency plots of the system detected by the X and Y axis sensors mounted on the spindle
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Vibration acceleration amplitude versus frequency plots from 0 to 1000 Hz for depth of cut of 1 mm, feed rate of 0.1 mm/tooth and cutting speed of 100 m/min: a) at room temperature (29°C) and b) at 350°C of preheating
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Vibration acceleration amplitude versus frequency plots from 1,000 Hz to 10,000 Hz for depth of cut of 1 mm, feed rate of 0.1 mm/tooth and cutting speed of 100 m/min: a) at room temperature (29°C) and b) at 350°C of preheating
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Vibration acceleration amplitude versus frequency plots up to 1000 Hz for depth of cut of 2 mm, feed rate of 0.2 mm/tooth and cutting speed of 300 m/min: a) at room temperature (29°C) and b) at 260°C of preheating
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Vibration acceleration amplitude versus frequency plots from 1,000 Hz to 10,000 Hz for depth of cut of 2 mm and feed rate of 0.2 mm/tooth and cutting speed of 300 m/min: a) at room temperature (29°C) and b) at 260°C of preheating
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Tool wear versus time graphs of medium carbon steel at cutting speed of 300 m/min, feed rate of 0.2 mm/tooth and depth of cut of 1 mm with and without preheating
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Tool wear versus time graphs of medium carbon steel at cutting speed of 300 m/min, feed rate of 0.2 mm/tooth and depth of cut of 2 mm with and without preheating
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Pictorial view of the tool nose area after machining at room temperature for case IV (Cutting condition: Cutting speed=300 m/min, depth of cut=2 mm and feed=0.2 mm per tooth)
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Pictorial view of the tool nose area after machining at preheated temperature of 260°C for case IV (Cutting condition: Cutting speed=300 m/min, depth of cut=2 mm and feed=0.2 mm per tooth)
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Micrograph of the workpiece material before machining
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Micrograph of the machined surface after machining with preheating at 350°C for case I (Cutting condition: Cutting speed=100 m/min, depth of cut=1 mm and feed=0.1 mm per tooth)
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Microstructure of chip after machining at room temperature for case I (Cutting condition: Cutting speed=100 m/min, depth of cut=1 mm and feed=0.1 mm per tooth)
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Microstructure of chip after machining with preheating at 350°C for case I (Cutting condition: Cutting speed=100 m/min, depth of cut=1 mm and feed=0.1 mm per tooth)

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