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Experimental study on the evolution of chip morphology, chip formation, and surface topography with cutting parameters, and their relationships in dry milling of cast aluminum alloy with PCD inserter

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Abstract

The evolution of chip morphology, chip formation, and surface topography (Ra, Rz) with cutting parameters has become an increasingly important way to achieve higher manufacturing efficiency and better surface topography. In this investigation, the relationships of chip morphology, chip formation, and surface topography with respect to cutting parameters are developed in dry milling of cast aluminum alloys with a PCD inserter. The feed rate affects the surface roughness, although no unanimous trend is observed between cutting parameters and surface topography. Surface crack propagation directly affects the saw-tooth chip morphology and the surface topography. The chip morphology is transformed from saw-tooth to continuous type at a chip deformation ratio of 3; chip deformation ratios of 2.5, 1.875, and 1.25 achieve cutting velocities of 32.71, 35.98, and 39.25 m/s, respectively, in which a continuous chip is formed by surface crack propagation and the predominant effect of thermal softening and surface topography is significantly improved.

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Acknowledgments

This work was supported by the Natural Science Foundation of Hunan Province (Grant No. 2020JJ411 5), and the National Natural Science Foundation of China (Grant Nos. 51535012, U1604255).

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Authors and Affiliations

  1. State Key Laboratory of High-performance Complex Manufacturing, Central South University, Changsha, 410083, China

    Xuelin Chen, Jinyuan Tang & Han Ding

  2. State Key Engineering Laboratory of Automobile Parts Design and Manufacturing, Institute of Automobile Parts Technology, Hunan Institute of technology, Hengyang, 421002, China

    Anmin Liu

Authors
  1. Xuelin Chen
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  2. Jinyuan Tang
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  3. Han Ding
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  4. Anmin Liu
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Corresponding authors

Correspondence to Jinyuan Tang or Han Ding.

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Recommended by Editor Hyung Wook Park

Xuelin Chen received his M.S. from the School of Mechanical and Automotive Engineering at South China University of Technology, China in 2014. He is a Ph.D. Candidate at Central South University. His research interests include machining dynamics, high-speed machining, ultrasonic vibration-assisted machining, and gear design.

Jinyuan Tang is a Professor at the School of Mechanical and Electrical Engineering and State Key Laboratory of High Performance Complex Manufacturing of Central South University, Changsha, PR China. His research interests include dynamics, gear design, machine design, and manufacturing.

Han Ding is an Associate Professor at the School of Mechanical and Electrical Engineering and State Key Laboratory of High Performance Complex Manufacturing of Central South University, Changsha, PR China. His research interests include gear design, machine design, and manufacturing.

Anmin Liu is a Professor at the Institute of Automobile Parts Technology and State Key Engineering Laboratory of Automobile Parts Design and Manufacturing of Hunan Institute of Technology, Hengyang, PR China. His research interests include high-speed machining and dynamics.

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Chen, X., Tang, J., Ding, H. et al. Experimental study on the evolution of chip morphology, chip formation, and surface topography with cutting parameters, and their relationships in dry milling of cast aluminum alloy with PCD inserter. J Mech Sci Technol 35, 1651–1662 (2021). https://doi.org/10.1007/s12206-021-0328-3

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  • DOI: https://doi.org/10.1007/s12206-021-0328-3

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