Surface topography modeling and roughness extraction in helical milling operation
- 86 Downloads
As a new hole-making method, helical milling has been widely used to machine holes on difficult-to-cut materials in the aircraft industry. The accurate prediction of the surface topography and the corresponding surface roughness are essential for optimizing the cutting conditions in order to improve the surface quality of the generated holes. In this paper, the kinematics of helical milling was first analyzed. Subsequently, a mathematical model was established to simulate the three-dimensional surface topography after a helical milling operation, in which the tool eccentricity, the secondary cutting, and also the size effect were taken into account. Further, an in-depth research on the process of extracting surface roughness from the surface topography was conducted. The proposed method is capable of extracting the roughness of the generated hole effectively, and meanwhile the predicted surface roughness is well in harmony with the experimental result. As a result, the developed model in this work can be used in planning and optimizing the cutting conditions.
KeywordsSurface topography Surface roughness Secondary cutting Phase shift Elastic recovery Helical milling
Unable to display preview. Download preview PDF.
- 3.Wang H, Qin X, Ren C, Wang Q (2012) Prediction of cutting forces in helical milling process. Int J Adv Manuf Technol 215(9):9–13Google Scholar
- 4.Zhou L, Ke Y, Dong H, Chen Z, Gao K (2016) Hole diameter variation and roundness in dry orbital drilling of CFRP/Ti stacks. Int J Adv Manuf Technol:1–14Google Scholar
- 5.Tian Y, Liu Y, Wang F, Jing X, Zhang D (2016) Modeling and analyses of helical milling process. Int J Adv Manuf Technol:1–20Google Scholar
- 6.Tönshoff HK, Friemuth T, Groppe M (2001) High efficient circular milling: a solution for economical machining of bore holes in composite materials. In Proceedings of the Third International Conference on High Speed Machining, 2001, 287–296, Metz (France)Google Scholar
- 14.Li SP, Liu DX, Li RH, Xia ML, Zhang W, Qiao MJ, Du DX (2012) Influence of shot peening and surface integrity on fatigue properties of TC21 titanium alloy. Mech Sci Technol Aerosp Eng 31(12):1921–1926 (in Chinese)Google Scholar
- 20.Shan YC, He N, Li L, Zhang T (2015) Research on hole surface roughness by orbital drilling of Ti6Al4V titanium alloy with simulation and test. Mach Tool Hydraul 43(19):46–50 (in Chinese)Google Scholar
- 21.Jiang YD, He GY, Qin XD, Zhao Q (2015) Study on surface integrity of hole in helical milling process of TC4 titanium alloy. Mech Sci Technol Aerosp Eng 34(10):1521–1525 (in Chinese)Google Scholar