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Effect of cutting parameters on cutting performance of nodular cast iron in ultra-fine-pitched milling

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Abstract

Nodular cast iron is widely used to manufacture various important mechanical components due to the comprehensive mechanical properties and relatively low cost. However, the machining efficiency and surface quality of nodular cast iron are difficult to be guaranteed because of the unstable cutting processing and severe tool wear. In this study, the effect of cutting parameters on the cutting performance of nodular cast iron in large size plane ultra-fine-pitched milling was systematically investigated. The dynamic milling force model showed that the milling force of multiple cutting edges was superimposed by the milling force of each cutting edge. When the number of cutting edges varied from 3 to 12, the cutting force increased linearly, while the average cutting force per tooth was almost the same and the cutting process became more stable. The cutting force also increased as the increase of cutting parameters, which was attributed to the strain-hardening effect. The roughness of machined surface decreased by ~ 39.7% with the increase of number of cutting edges from 3 to 12. The increase of feed rate per tooth could reduce the tensile residual stress on the machined surface. The burr on chip edges decreased, and the degree of chip deformation increased with the increase of the number of cutting edges. The tool failure mode was the adhesive wear of the rake face. With the increase of the number of cutting edges in the ultra-fine-pitched milling, the cutting efficiency and tool life could be significantly improved.

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Abbreviations

F (j):

Milling force of the j-th blade

F x (j):

X-Component force of the j-th blade in Cartesian coordinate

F y (j):

Y-Component force of the j-th blade in Cartesian coordinate

F z (j):

Z-Component force of the j-th blade in Cartesian coordinate

F r (j):

Radial component force of the j-th blade in cylindrical coordinate

F t (j):

Tangential component force of the j-th blade in cylindrical coordinate

F a (j):

Axial component force of the j-th blade in cylindrical coordinate

γ r :

Radial rake angle

γ a :

Axial rake angle

F f (j):

Friction force of the j-th blade

F n (j):

Normal component force of the j-th blade

η c :

Angle between radial component force and normal component force

θ j :

Rotated angle of the j-th blade

r (θ j):

Radial cutting thickness

K t :

Tangential cutting force coefficient

K r :

Radial cutting force coefficient

K a :

Axial cutting force coefficient

K n :

Normal cutting force component coefficient of milling cutter face

K f :

Friction component coefficient of milling cutter face

r jc :

Displacement of the j-th blade in the r direction

r jcl :

Displacement of the (j–1)-th blade in the r direction

f jt :

Displacement of the j-th blade in the Ft (j) direction

x jcl :

Displacement of the (j–1)-th blade in the X direction

y jcl :

Displacement of the (j–1)-th blade in the Y direction

γ L :

Tool cutting edge angle

x jc :

Displacement of the j-th blade in the X direction

y jc :

Displacement of the j-th blade in the Y direction

z jc :

Displacement of the j-th blade in the Z direction

Δ:

Dynamic relative displacement of the j-th blade

θ s :

Angular displacements of the blade at the entry points

θ e :

Angular displacements of the blade at the exit points

F xs(j):

Static milling force in the X direction

F ys(j):

Static milling force in the Y direction

F zs(j):

Static milling force in the Z direction

γ 0 :

Rake angle

α 0 :

Clearance angle

γ ε :

Edge radius

v :

Cutting speed

f z :

Feed rate per tooth

S a :

Average surface roughness

a p :

Cutting depth

z :

Number of cutting edges

ε z(i):

Axial runout error of the i-th cutting edge

ε x(i):

Radial runout error of the i-th cutting edge

Δr :

Interval of sampling points on the X-axis

r :

Radius of the tool tip arc

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Funding

This work was supported by the National Natural Science Foundation of China, China (Grant numbers 52175376 and 52075040).

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Authors and Affiliations

  1. School of Mechanical Engineering, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081, People’s Republic of China

    Jie Sun & Peng Wang

  2. Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing, 100081, People’s Republic of China

    Wenxiang Zhao, Pei Yan, Li Jiao & Xibin Wang

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  1. Jie Sun
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Correspondence to Pei Yan.

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Sun, J., Zhao, W., Yan, P. et al. Effect of cutting parameters on cutting performance of nodular cast iron in ultra-fine-pitched milling. Int J Adv Manuf Technol 121, 4387–4402 (2022). https://doi.org/10.1007/s00170-022-09618-x

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