Abstract: Many orthopedic implants like proximal humerus cases require lower surface roughness and almost immediate/short lead time surgery. Thus, rapid response from the manufacturer is very crucial. Tool path strategy of milling process has a direct influence on the surface roughness and lead time of medical implant. High-speed milling as promised process would improve the machined surface quality, but conventional or super-abrasive grinding still required which imposes some drawbacks such as additional costs and time. Currently, many CAD/CAM software offers some different tool path strategies to milling free form surfaces. Nevertheless, the users must identify how to choose the strategies according to cutting tool geometry, geometry complexity, and their effects on the machined surface. This study investigates the effect of different tool path strategies for milling a proximal humerus head during finishing operation on stainless steel 316L. Experiments have been performed using MAHO MH700 S vertical milling machine and four machining strategies, namely, spiral outward, spiral inward, and radial as well as zig-zag. In all cases, the obtained surfaces were analyzed in terms of roughness and dimension accuracy compared with those obtained by simulation. The findings provide evidence that surface roughness, dimensional accuracy, and machining time have been affected by the considered tool path strategy.
Abstract: The wear of cutting tool degrades the quality of the product in the manufacturing processes. The on line monitoring of the cutting tool wear level is very necessary to prevent the deterioration of the quality of machining. Unfortunately there is not a direct manner to measure the cutting tool wear on line. Consequently we must adopt an indirect method where wear will be estimated from the measurement of one or more physical parameters appearing during the machining process such as the cutting force, the vibrations, or the acoustic emission etc…. In this work, a neural network system is elaborated in order to estimate the flank wear from the cutting force measurement and the cutting conditions.
Abstract: Through a proper analysis of residual strain and stress
distributions obtained at the surface of high speed milled specimens
of AA 6082–T6 aluminium alloy, the performance of an improved
indentation method is evaluated. This method integrates a special
device of indentation to a universal measuring machine. The
mentioned device allows introducing elongated indents allowing to
diminish the absolute error of measurement. It must be noted that the
present method offers the great advantage of avoiding both the
specific equipment and highly qualified personnel, and their inherent
high costs. In this work, the cutting tool geometry and high speed
parameters are selected to introduce reduced plastic damage.
Through the variation of the depth of cut, the stability of the shapes
adopted by the residual strain and stress distributions is evaluated.
The results show that the strain and stress distributions remain
unchanged, compressive and small. Moreover, these distributions
reveal a similar asymmetry when the gradients corresponding to
conventional and climb cutting zones are compared.
Abstract: The objective of this research was to study factors,
which were affected on surface roughness in high speed milling of
hardened tool steel. Material used in the experiment was tool steel JIS
SKD 61 that hardened on 60 ±2 HRC. Full factorial experimental
design was conducted on 3 factors and 3 levels (3
3
designs) with 2
replications. Factors were consisted of cutting speed, feed rate, and
depth of cut. The results showed that influenced factor affected to
surface roughness was cutting speed, feed rate and depth of cut which
showed statistical significant. Higher cutting speed would cause on
better surface quality. On the other hand, higher feed rate would cause
on poorer surface quality. Interaction of factor was found that cutting
speed and depth of cut were significantly to surface quality. The
interaction of high cutting speed associated with low depth of cut
affected to better surface quality than low cutting speed and high depth
of cut.