Research Papers

Analytical Modeling of Chip Geometry in High-Speed Ball-End Milling on Inclined Inconel-718 Workpieces

[+] Author and Article Information
Harshad A. Sonawane

Mechanical Engineering Department,
Indian Institute of Technology Bombay,
Mumbai 400076, India

Suhas S. Joshi

Mechanical Engineering Department,
Indian Institute of Technology Bombay,
Mumbai 400076, India
e-mail: ssjoshi@iitb.ac.in

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received July 16, 2013; final manuscript received September 17, 2014; published online November 26, 2014. Assoc. Editor: Burak Ozdoganlar.

J. Manuf. Sci. Eng 137(1), 011005 (Feb 01, 2015) (12 pages) Paper No: MANU-13-1279; doi: 10.1115/1.4028635 History: Received July 16, 2013; Revised September 17, 2014; Online November 26, 2014

Most often contoured surfaces inclined at several inclinations are generated using ball-end milling of aerospace and automobile components. It is understood that the chip morphology and the corresponding cutting mechanisms change with a change in the tool-workpiece interactions on inclined surfaces. Analytical predictive models to accurately evaluate the undeformed and deformed geometries of chip in ball-end milling are not available. Therefore, this work presents development of analytical models to predict the cutting tool-workpiece interaction as the workpiece inclination changes, in terms of undeformed and deformed chip cross sections. The models further evaluate instantaneous shear angle along any cross section of the tool-work interaction on a ball-end cutter in a milling operation. The models illustrate evaluation of a chip segment and mechanism of its formation in ball-end milling on an inclined work surface. It is observed that the chip dimensions, except deformed chip thickness, increase with an increase in the workpiece inclination angle. Also, a higher workpiece inclination results into an easy flow of the deformed chip over the cutting tool flank, which leads to a higher shear angle during the cut. The predictive chip geometry models corroborate 90% to the experimental results obtained at various workpiece inclinations.

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Fig. 1

(a) Cutting tool-workpiece interactions at various workpiece inclinations, (b) theme of the analytical models, and (c) model validation

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Fig. 2

(a) Tool geometry for ball end mill cutter, (b) top view of chip element at tool rotation angle θ in + Y-axis [9], (c) ball-end mill tool with various inclined workpiece surfaces, and (d) details of instantaneous depth of cut Zδ as a function of workpiece inclination angle δ

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Fig. 3

Comparison between (a) undeformed chip positions and (b) undeformed chip geometries at any workpiece inclination angle

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Fig. 4

(a) Undeformed chip width geometry and (b) comparison between undeformed chip width at workpiece with and without inclination

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Fig. 5

Undeformed chip length at workpiece with and without inclination

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Fig. 6

Geometry of ball-end mill tool for evaluation of deformed chip length, inset: chip length at horizontal and workpiece inclined at any other angle

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Fig. 10

Predicted deformed chip length at different workpiece inclinations

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Fig. 11

Predicted instantaneous shear angle at various workpiece inclinations

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Fig. 7

Predicted undeformed chip thicknesses at different workpiece inclinations

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Fig. 8

Predicted undeformed chip widths at different workpiece inclinations

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Fig. 9

Predicted deformed chip thickness at different workpiece inclinations

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Fig. 14

Qualitative and quantitative comparison of deformed chip geometries at various workpiece inclinations

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Fig. 15

Predicted and the experimental deformed chip (a) length, (b) width, and (c) thickness at various workpiece inclinations

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Fig. 16

Validation of analytical cutting force models at 0 deg, 15 deg, and 45 deg workpiece inclinations with the average experimental data at a constant machining parameters (Vc = 50 m/min, f = 0.06 mm/tooth, and Z = 1 mm)

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Fig. 12

Schematic of workpiece mounting system (a) at 0 deg, (b) at 15 deg, and (c) at 45 deg

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Fig. 13

(a)–(i) Micrographs of the deformed chips at various workpiece inclinations



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