Modeling of cutting force in micro-end-milling process with experimental validation on additive manufactured Nickel-based superalloy
Nowadays aerospace, microelectronics, biotechnology industries require small sized components with complex shape and high mechanical properties, often operating in aggressive environment. In this framework, Additive Manufacturing (AM) of Nickel-based superalloys is an interesting and cost effective...
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Published in | Procedia CIRP Vol. 102; pp. 222 - 227 |
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Main Authors | , , , |
Format | Journal Article |
Language | English |
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Elsevier B.V
2021
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Abstract | Nowadays aerospace, microelectronics, biotechnology industries require small sized components with complex shape and high mechanical properties, often operating in aggressive environment. In this framework, Additive Manufacturing (AM) of Nickel-based superalloys is an interesting and cost effective process. Fewer design constraints and the weight reduction achievable through the topology optimization are the most relevant AM advantages. Furthermore, micro-scale features on the additively fabricated parts can be manufactured by using micro machining. Subtractive processes ensure to achieve high-precision mechanical coupling due to better surface finishes and tighter tolerances. A lack of scientific studies focusses on the material removal behavior of difficulty-to-cut alloys produced via Additive Manufacturing is evident. This work describes a machining analytical force models which considers the presence of ploughing- and shearing- dominated cutting regimes. The undefined cutting force model parameters and the Minimum Uncut Chip Thickness (MUCT) can be identified through proper experimental tests. The refinement procedure of the model was utilized to characterize Inconel 625 samples fabricated by LaserCUSINGTM. The cutting force data were elaborated with an iterative methodology based on a search algorithm. The model successfully predicted how the cutting force changes as a function of the process parameters. |
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AbstractList | Nowadays aerospace, microelectronics, biotechnology industries require small sized components with complex shape and high mechanical properties, often operating in aggressive environment. In this framework, Additive Manufacturing (AM) of Nickel-based superalloys is an interesting and cost effective process. Fewer design constraints and the weight reduction achievable through the topology optimization are the most relevant AM advantages. Furthermore, micro-scale features on the additively fabricated parts can be manufactured by using micro machining. Subtractive processes ensure to achieve high-precision mechanical coupling due to better surface finishes and tighter tolerances. A lack of scientific studies focusses on the material removal behavior of difficulty-to-cut alloys produced via Additive Manufacturing is evident. This work describes a machining analytical force models which considers the presence of ploughing- and shearing- dominated cutting regimes. The undefined cutting force model parameters and the Minimum Uncut Chip Thickness (MUCT) can be identified through proper experimental tests. The refinement procedure of the model was utilized to characterize Inconel 625 samples fabricated by LaserCUSINGTM. The cutting force data were elaborated with an iterative methodology based on a search algorithm. The model successfully predicted how the cutting force changes as a function of the process parameters. |
Author | Attanasio, Aldo Loda, Dario Abeni, Andrea Özel, Tuğrul |
Author_xml | – sequence: 1 givenname: Andrea surname: Abeni fullname: Abeni, Andrea email: andrea.abeni@unibs.it organization: University of Brescia, Via Branze 38, 25123 Brescia, Italy – sequence: 2 givenname: Dario surname: Loda fullname: Loda, Dario organization: University of Brescia, Via Branze 38, 25123 Brescia, Italy – sequence: 3 givenname: Tuğrul surname: Özel fullname: Özel, Tuğrul organization: Rutgers University, Industrial & Systems Engineering, Piscataway, New Jersey, USA – sequence: 4 givenname: Aldo surname: Attanasio fullname: Attanasio, Aldo organization: University of Brescia, Via Branze 38, 25123 Brescia, Italy |
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Keywords | Analytical model Inconel 625 MUCT Micro machining Cutting force |
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Title | Modeling of cutting force in micro-end-milling process with experimental validation on additive manufactured Nickel-based superalloy |
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