Abstract
Further progress in green cutting applications depends on the innovativeness of machine tools, advances in tool development, and, especially, more complex tool and cutting technologies. Therefore, this study analyzes the factors influencing high-speed cutting performance. Grey relational analysis and the Taguchi method are then incorporated in the experimental plan with high-speed milling of AISI H13 tool steel. Experimental results indicate that the contributions of tool grinding precision, geometric angle, and cutting conditions to the multiple quality characteristics of high-speed milling for AISI H13 tool steel are 11.75, 9.80, and 73.11 %, respectively. For rough machining, tool life and metal removal volume are the primary evaluation indicators and cutting parameters should be prioritized, especially cutting speed and feed per tooth. In finish machining, workpiece surface roughness is the primary evaluation indicator. Besides the selection of cutting parameters, the design and grinding of endmill are critical factors, especially the design and grinding of relief angles.
Article PDF
References
Li L, He N, Wang M, Wang ZG (2002) High speed cutting of Inconel 718 with coated carbide and ceramic inserts. J Mater Process Technol 129:127–130
Dolinsek S, Sustarsic B, Kopac J (2001) Wear mechanisms of tools in high speed cutting process. Wear 250:349–356
Schulz H, Moriwaki T (1992) High-speed machining. CIRP Ann-Manuf Technol 41:637–643
Fallböhmer P, Rodríguez CA, Özel T, Altan T (2000) High-speed machining of cast iron and alloy steels for die and mold manufacturing. J Mater Process Technol 98:104–115
Cui XB, Znao J, Tian XH (2013) Cutting forces, chip formation, and tool wear in high-speed face milling of AISI H13 steel with CBN tools. Int J Adv Manuf Technol 64:1737–1749
Fahad M, Mativenga PT, Sheikh MA (2012) A comparative study of multilayer and functionally graded coated tools in high-speed machining. Int J Adv Manuf Technol 62:43–57
Cui XB, Zhao J, Jia C, Zhou YH (2012) Surface roughness and chip formation in high-speed face milling AISI H13 steel. Int J Adv Manuf Technol 61:1–13
Benardos PG, Vosniakos GC (2003) Predicting surface roughness in machining a review. Int J Mach Tool Manuf 43:838–844
Yin L, Spowage AC, Ramesh K, Huang H, Pickering JP, Vancoille EYJ (2003) Influence of microstructure on ultra-precision grinding of cemented carbides. Int J Mach Tool Manuf 44:533–543
Kwak JS (2004) Application of Taguchi and response surface methodologies for geometric error in surface grinding process. Int J Mach Tool Manuf 45:327–334
Kopac K, Krajnik P (2006) High-performance grinding—a review. J Mater Process Technol 175:278–284
Abdullah A, Pak A, Farahi M, Barzegari M (2007) Profile wear of resin-bonded nickel-coated diamond wheel and roughness in creep-feed grinding of cemented tungsten carbide. J Mater Process Technol 183:165–168
Ross PJ (1988) Taguchi techniques for quality engineering. McGraw-Hill, New York
Ghani JA, Choudhury IA, Hassan HH (2004) Application of Taguchi method in the optimization of end milling parameters. J Mater Process Technol 145:84–92
Saglam H, Yaldiz S, Unsacar F (2007) The effect of tool geometry and cutting speed on main cutting force and tool tip temperature. Mater Des 28:101–111
Çiçek A, Kıvak T, Samtaş G (2012) Application of Taguchi method for surface roughness and roundness error in drilling of AISI 316 stainless steel. Strojniski Vestn J Mech Eng 58:165–174
Deng JL (1989) Introduction to Grey system theory. J Grey Syst 1:1–24
Tsao CC (2009) Grey–Taguchi method to optimize the milling parameters of aluminum alloy. Int J Adv Manuf Technol 40:41–48
Gopalsamy BM, Mondal B, Ghosh S (2009) Optimization of machining parameters for hard machining grey relational theory approach and ANOVA. Int J Adv Manuf Technol 45:1068–1086
Lu HS, Chang CK, Hwang NC, Chung CT (2009) Grey relational analysis coupled with principal component analysis for optimization design of the cutting parameters in high-speed end milling. J Mater Process Technol 209:3808–3817
Sahoo AK, Baral AN, Rout AK, Routra BC (2012) Multi-objective optimization and predictive modeling of surface roughness and material removal rate in turning using grey relational and regression analysis. Procedia Eng 38:1606–1627
Tosun N (2006) Determination of optimum parameters for multi-performance characteristics in drilling by using grey relational analysis. Int J Adv Manuf Technol 26:450–455
Chang CK, Lu HS (2007) Design optimization of cutting parameters for side milling operations with multiple performance characteristics. Int J Adv Manuf Technol 32:18–26
Wang YC, Chen CH, Lee BY (2012) The design model of micro end-mills by the finite element method. Trans FAMENA 36:41–50
Chen CH, Wang YC, Lee BY (2012) The effect of surface roughness of end-mills on optimal cutting performance for high-speed machining. Strojniski Vvestn J Mech Eng 59:124–134
Chen JY, Lee BY, Chen CH (2007) Planning and analysis of grinding processes for end mills of cemented tungsten carbide. J Mater Process Technol 201:618–622
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Open Access This article is distributed under the terms of the Creative Commons Attribution License which permits any use, distribution, and reproduction in any medium, provided the original author(s) and the source are credited.
About this article
Cite this article
Wang, YC., Chen, CH. & Lee, BY. Analysis model of parameters affecting cutting performance in high-speed machining. Int J Adv Manuf Technol 72, 521–530 (2014). https://doi.org/10.1007/s00170-013-5505-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-013-5505-9