Influence of micro-structured milling cutter on the milling load and surface roughness of 6061 aluminum alloy
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ORIGINAL ARTICLE
Influence of micro-structured milling cutter on the milling load and surface roughness of 6061 aluminum alloy Jianfeng Pan 1 & Jing Ni 2 & Lihua He 2 & Zhi Cui 2 & Kai Feng 2 Received: 10 May 2020 / Accepted: 14 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract During the milling process, milling load and micro-vibration reduction may significantly improve the machining performance. Micro-structuring of the milling tool is one of the perspective approaches, providing force reduction and vibration suppression. In this work, two kinds of micro-structures grooved on the tool rake face have been investigated during aluminum alloy cutting: linear grooves (LG) and V-shaped grooves (VG). Milling load and the surface quality of the machined workpiece were selected to assess the milling performance of the selected tools. The results indicated that the VG milling tool showed the best performance with the reduced average milling load FX, FY, and FZ up to 9.27%, 21.98%, and 12.44% and root mean square error of FY up to 6.94% compared with a conventional milling tool. Moreover, the usage of the VG milling tool could achieve less galling wear and scratch marks on the machined surface, providing the smallest surface roughness of 0.541. Keywords Micro-structure . Milling cutter . Milling load . Surface roughness . 6061 aluminum alloy
1 Introduction Aluminum alloys are easy-to-cut materials with medium-tohigh strength, low cost, and high strength-to-weight ratio widely used in structural automobile, aerospace, and bioengineering industries [1]. However, such soft materials often demonstrate chip adhesion during the machining process, especially milling. The complicated interaction of the chip-tool interface leads to the increase of the cutting load and microvibration during the cutting process, affecting the machining quality. Hence, more attention towards approaches, improving the milling performance during the aluminum alloys machining, is required. The milling tool, being a standard machining resource, directly determines the machining performance [2]. Therefore, considerable efforts have been made in order to
* Lihua He [email protected] 1
Special Equipment Institute, Hangzhou Vocational and Technical College, Hangzhou, China
2
School of Mechanical Engineering, Hangzhou Dianzi University, No. 1158 The Second Avenue, Baiyang Subdistrict, Qiantang New District, Hangzhou 310018, Zhejiang Province, China
improve the cutting performance, mainly through the microstructuring of the milling tool. There are different ways to create micro-structures, which mainly include electric discharge machining (EDM), focused ion beam (FIB) lithography, mechanical ablation, and laser ablation. Thus, Koshy et al. successfully performed linear surface micro-structuring on steel cutters, using EDM technology [3]. Kim et al. also used EDM technology for the surfacetexturing of the cubic boron nitride (CBN) tool [4]. Obiawa et al. prepared four kinds of micro-structured tools with horizontal,
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