Jayakumar Santhakumar, Kannan Sathish, Iqbal U Mohammed
Department of Mechanical Engineering, Faculty of Engineering and Technology, SRM Institute of Science and Technology, Kattankulathur Campus, Chennai 603203, Tamil Nadu, India.
Department of Mechanical Engineering, Amity University, Dubai 345019, United Arab Emirates.
Materials (Basel). 2024 Sep 14;17(18):4519. doi: 10.3390/ma17184519.
The selection of the right tool path trajectory and the corresponding machining parameters for end milling is a challenge in mold and die industries. Subsequently, the selection of appropriate tool path parameters can reduce overall machining time, improve the surface finish of the workpiece, extend tool life, reduce overall cost, and improve productivity. This work aims to establish the performance of end milling process parameters and the impact of trochoidal toolpath parameters on the surface finish of AISI D3 steel. It especially focuses on the effect of the tool tip nose radius deviation on the surface quality using precision measurement techniques. The experimental design was carried out in a systematic manner using a face-centered central composite design (FCCD) within the framework of response surface methodology (RSM). Twenty different experiment trials were conducted by changing the independent variables, such as cutting speed, feed rate, and trochoidal pitch distance. The main effects and the interactions of these parameters were determined using analysis of variance (ANOVA). The optimal conditions were identified using a multiple objective optimization method based on desirability function analysis (DFA). The developed empirical models showed statistical significance with the best process parameters, which include a feed rate of 0.05 m/tooth, a trochoidal pitch distance of 1.8 mm, and a cutting speed of 78 m/min. Further, as the trochoidal pitch distance increased, variations in the tool tip cutting edge were observed on the machined surface due to peeling off of the coating layer. The flaws on the tool tip, which alter the edge micro-geometry after machining, resulted in up to 33.83% variation in the initial nose radius. Deviations of 4.25% and 5.31% were noted between actual and predicted values of surface roughness and the nose radius, respectively.
在模具行业中，为立铣选择合适的刀具路径轨迹和相应的加工参数是一项挑战。随后，选择合适的刀具路径参数可以减少整体加工时间、提高工件的表面光洁度、延长刀具寿命、降低总成本并提高生产率。这项工作旨在确定立铣工艺参数的性能以及摆线刀具路径参数对AISI D3钢表面光洁度的影响。它特别关注使用精密测量技术时刀尖圆角半径偏差对表面质量的影响。实验设计是在响应面方法（RSM）框架内使用面心中心复合设计（FCCD）系统地进行的。通过改变切削速度、进给速度和摆线节距距离等自变量进行了20次不同的实验试验。使用方差分析（ANOVA）确定这些参数的主要影响和相互作用。使用基于合意性函数分析（DFA）的多目标优化方法确定了最佳条件。所建立的经验模型显示了最佳工艺参数具有统计学意义，这些参数包括进给速度为0.05 m/齿、摆线节距距离为1.8 mm和切削速度为78 m/min。此外，随着摆线节距距离的增加，由于涂层剥落，在加工表面上观察到刀尖切削刃的变化。刀尖上的缺陷在加工后改变了刃口微观几何形状，导致初始圆角半径变化高达33.83%。表面粗糙度和刀尖圆角半径的实际值与预测值之间分别存在4.25%和5.31%的偏差。
