Masters Theses

Abstract

"This thesis presents the results of the investigations of mechanistic modeling and simulation of cutting forces in high speed end milling of titanium alloy, Ti-6Al-4V, and the determination of specific cutting and edge force coefficients for carbide bull-nose helical end-mill. A generalized mathematical model representing the outer geometry of an end-mill and the cutter edge geometry is presented. Mechanistic cutting force models have been developed for a general helical end-mill and modeled specifically for a bullnose helical end-mill. A MATLAB code for the mechanistic cutting force models have been developed for the simulation of cutting force components in end milling and for the determination of specific cutting and edge force coefficients for any workpiece-tool material pair. Specific cutting and edge force coefficients are obtained for carbide bullnose helical end-mill - titanium alloy workpiece material pair at 10% radial immersion up-milling experiments. The effects of machining parameters: feed per tooth, helix angle, axial depth of cut, corner radius, number of cutter flutes, and spindle speed on cutting forces were investigated. End milling experiments were conducted on titanium alloy, Ti-6Al-4V, using a 0.5 inch (12.7 mm) diameter carbide bull-nose helical end-mill to verify the models. Predicted cutting force components (Fx, Fy, and Fz) obtained by the mechanistic cutting force models were compared with measured experimental values, and also with predicted and measured values from published literature. The results were in good agreement in both cases. This method for the determination of specific force coefficients and predicting cutting forces for titanium alloys can easily be extended to other metal alloys such as Hastelloy, Inconel, and niobium alloys"--Abstract, page iv.

Advisor(s)

Okafor, A. Chukwujekwu (Anthony Chukwujekwu)

Committee Member(s)

Chandrashekhara, K.
Lin, Dan

Department(s)

Mechanical and Aerospace Engineering

Degree Name

M.S. in Mechanical Engineering

Sponsor(s)

National Science Foundation (U.S.)

Comments

Financial support of the National Science Foundation under grant no. CMMI 800871

Publisher

Missouri University of Science and Technology

Publication Date

Fall 2011

Journal article titles appearing in thesis/dissertation

  • Development of virtual CNC machine tools and web-based machining process simulation - Part 1: Mechanistic cutting force models and determination of specific force coefficients in helical end milling
  • Development of virtual CNC machine tools and web-based machining process simulation - Part 2: Determination of specific force coefficients and simulation of cutting force components in high speed bull-nose end milling of titanium alloys

Pagination

xi, 152 pages

Note about bibliography

Includes bibliographical references.

Rights

© 2011 Vinay Rao Talekar, All rights reserved.

Document Type

Thesis - Open Access

File Type

text

Language

English

Subject Headings

Titanium alloys -- Machinability
Milling (Metal-work)
Metal-cutting tools -- Design
Machining -- Evaluation


Thesis Number

T 9947

Print OCLC #

801698180

Electronic OCLC #

914468313

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