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Surface roughness prediction with new barrel-shape mills considering runout: Modelling and validation

Urbikain Pelayo, G. ; Olvera-Trejo, D. ; Luo, M. ; López de Lacalle, L.N. ; Elías-Zuñiga, A.

Measurement : journal of the International Measurement Confederation, 2021-03, Vol.173, p.108670, Article 108670 [Periódico revisado por pares]

London: Elsevier Ltd

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  • Título:
    Surface roughness prediction with new barrel-shape mills considering runout: Modelling and validation
  • Autor: Urbikain Pelayo, G. ; Olvera-Trejo, D. ; Luo, M. ; López de Lacalle, L.N. ; Elías-Zuñiga, A.
  • Assuntos: Aluminum ; Aluminum alloys ; Barrel tools ; Cutting parameters ; Disks ; End milling ; Fatigue strength ; Geometrical model ; Geometry ; High speed machining ; Impellers ; Mathematical models ; Milling (machining) ; Mills ; Surface geometry ; Surface properties ; Surface roughness ; Three dimensional models ; Titanium alloys ; Titanium base alloys ; Wear resistance
  • É parte de: Measurement : journal of the International Measurement Confederation, 2021-03, Vol.173, p.108670, Article 108670
  • Descrição: •Surface roughness in barrel milling operations considering runout was modelled.•Geometry-based and mathematical-based models were developed for barrel tools.•Favorable agreement was found between simulated surface roughness and experimental values.•Relative errors below 10–15% were found in most cases.•Quasi-static models seem suitable for both tested materials Al7075T6 and Ti6Al4V. Complex aeronautic components such as impellers and blade disks require barrel-end mills having complex geometries to reproduce freeform surfaces. On these parts, the specified surface quality has a key role in wear resistance, ductility and fatigue strength. So, controlling surface roughness is a key factor in the machining process. This work proposes two approaches: 1) a geometrical model of the surfaces being created when using barrel-end mills. It is based on simulating the marks left by the tool on the machined surface; 2) empirical models for a surface prediction based on the cutting parameters. Both approaches were applied to the milling of aluminum Al7075T6 and titanium Ti6Al4V alloys. The experimental roughness was obtained by measuring the surface roughness at the center of the shell-form geometry left by the tool. In general, results show a good agreement between predicted and measured surface roughness for both materials and both approaches. Results lead to relative errors below 15% (geometry-based model) and 10% (empirical models) in most cases. While mathematical models are more accurate, a good basis was obtained with the geometrical model for a more complete 3D characterization of surface topographies using these tools.
  • Editor: London: Elsevier Ltd
  • Idioma: Inglês
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  • Realização: ABCD-USP USP   Logos de Redes Sociais: Freepik

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