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Experimental investigation of tool wear and its effect on TiSiN-coated ball-end mill geometry in high-speed milling

  • Rami BelguithEmail author
  • Maher Baili
  • Lotfi Sai
  • Mihed Ben Said
  • Gilles Dessein
  • Wassila Bouzid
ORIGINAL ARTICLE
  • 31 Downloads

Abstract

In this paper, an experimental investigation was carried out in order to identify the tool life of sintered carbide ball-end mill based on spindle speed variation. The used tool is coated with titanium silicon nitride “TiSiN” which is a high-hardened and high heat-resistant coat. Experiments were conducted on parallelepiped plane workpieces on AISI 4142 during high-speed milling. Two kinds of tests were realized, the first is a wear experiment using high cutting parameters in order to identify the wear criterion model as a function of the spindle speed. The second one is an accelerated wear experiment to develop an empirical model for the tool life. The research revealed that the tool life and wear criterion value decrease when increasing the spindle speed. It is observed that the wear increases linearly in the normal wear zone. Furthermore, the effect of tool wear on the ball-end mill geometry and the cutting parameters were also investigated. A noticeable variation was found on the effective radius of the tool which affect the tool geometry such as the direction angles of the elementary cutting edge which results in the variation of the cutting parameters. An important effect also of the effective radius variation on the cutting speed was proved.

Keywords

Ball-end mill Wear TiSiN coat Tool life Wear criterion value Tool geometry High-speed milling 

Nomenclature

fz

Feed per tooth (mm/tooth)

N

Spindle speed (RPM)

Nf

Number of flutes

VB

Flank wear (mm)

T

Tool life (min)

R

Discretized radius (mm)

Pa

Discretization plane

Ps

Edge tangential plane

Pn

Normal plane

γo(z)

Rake angle in the plane Po (rad)

λs(z, t)

Cutting edge angle in the plane Ps

i0

Helix angle (°)

\( {\theta}_{V_Bo}\left(z,t\right) \)

Offset angle due to flank wear in the plane Po

\( {\theta}_{V_Ba}\left(z,t\right) \)

Offset angle due to flank wear in the plane Pa

ψ(θ, z, t)

Angular position of each increment (rad)

tn(θ, z)

Uncut chip thickness (mm)

ψlimlim

Limit angles of the engaged tool/workpiece area (rad)

a,g

Wear criterion model constants

c,d

Tool life model constants

r

Common difference between levels

z

The height of discretized disk

Δt

The milling duration of each surface (min)

θ(t)

Rotational angle (°)

ae

Radial depth of cut

ap

Axial depth of cut

VB*

Flank wear criterion value (mm)

Rn

Nominal radius (mm)

Rn0

Initial nominal radius (mm)

Pr

Reference plane

Po

Orthogonal plane

κ(z, t)

Direction angle of each increment (rad)

γa

Rake manufacturer angle in the plane Pa

αa

Clearance manufacturer angle in the plane Pa

iL(z,t)

Local helix angle (°)

αo(z)

Clearance angle projection in the plane Po (rad)

γn(z)

Rake angle in the plane Pn (rad)

φ(z, t)

Angular position of each increment from tooth tangent (rad)

db(z,t)

Chip width (mm)

ΔVB

The flank wear measured after the milling of one surface (mm)

t

Time (min)

k

Wear constant

Δz

The height of the elementary disk (mm)

Vf

Feed rate (mm/min)

Notes

Acknowledgments

The work is carried out thanks to the support and funding allocated to the Unit of Mechanical and Materials Production Engineering (UGPMM / UR17ES43) by the Tunisian Ministry of Higher Education and Scientific Research.

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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.Unité de Génie de Production Mécanique et Matériaux, ENISSfaxTunisia
  2. 2.LGP- ENITUniversité de ToulouseTarbesFrance

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