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Research Papers

A Model to Determine the Effect of Tool Diameter on the Critical Feed Rate for Ductile-Brittle Transition in Milling Process of Brittle Material

[+] Author and Article Information
Muhammad Arif1

Department of Mechanical Engineering,  National University of Singapore, 9 Engineering Drive 1, Singapore 117576, Singaporearif@nus.edu.sg

Mustafizur Rahman

Department of Mechanical Engineering,  National University of Singapore, 9 Engineering Drive 1, Singapore 117576, Singaporempemusta@nus.edu.sg

Wong Yoke San

Department of Mechanical Engineering,  National University of Singapore, 9 Engineering Drive 1, Singapore 117576, Singaporempewys@nus.edu.sg

1

Corresponding author.

J. Manuf. Sci. Eng 134(5), 051012 (Sep 21, 2012) (8 pages) doi:10.1115/1.4007462 History: Received February 13, 2011; Revised June 12, 2012; Published September 21, 2012; Online September 21, 2012

This paper presents analytical and experimental results of ductile-mode machining of brittle material by milling process. In milling process of brittle material, feed per edge is the predominant parameter to achieve ductile-mode machining and hence it limits the permissible material removal rate. An analytical model has been proposed to evaluate the effect of tool diameter on the critical feed per edge for ductile-brittle transition in milling process of brittle material. The proposed model has been validated experimentally by performing microcutting tests on tungsten carbide workpiece by milling process. It has been established by the model and the experimental results that an end-mill of larger diameter improves the critical feed per edge for ductile-brittle transition in milling process of brittle material.

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Copyright © 2012 by American Society of Mechanical Engineers
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Figures

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Figure 1

Side cutting of brittle material with upmilling technique at (a) low feed per edge and (b) high feed per edge [17]

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Figure 2

Schematic geometry of up-milling cut in machining of brittle material

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Figure 3

Influence of tool diameter on height of fracture onset point from the plane of machined surface

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Figure 4

Median and lateral cracks’ orientation during upmill cut

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Figure 5

Schematic critical angles for two cutters of different diameters

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Figure 6

(a) Vertical spindle machine tool and (b) schematic of milling cutter

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Figure 7

Experimental setup and plan

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Figure 8

Surfaces machined at rd = 1.0 mm, cutting speed = 47 mm/min and (a) fe = 18.5 μm with cutter dia = 5 mm, (b) fe = 21.5 μm, cutter dia = 8 mm, (c) fe = 21.5 μm, cutter dia = 5 mm

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Figure 9

Machining force signal (rd = 1.0 mm, fe = 18.5 μm, cutting speed = 47 m/min, cutter diameter = 5.0 mm)

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Figure 10

Predicted values of critical feed per edge for different diameter cutters (a) both by considering and without considering radial crack configuration and (b) with radial configuration only

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Figure 11

Surfaces machined with 8 mm diameter cutter at cutting speed = 47 m/min, fe = 30.5 μm and (a) rd = 200 μm, (b) rd = 1 mm

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