Laboratory and simulation study of the effect of the parameters of

the milling machine on the smoothness of the surface of alloy steel

* **
Alireza salehikahyesh , Iman Gol shokooh
*asalehikahyesh@gmail.com MSC head making and producing in Mechanical
Engineering,IslamicAzadUniversityofDoroud

**Golshokooh@yahoo.comFacultymemberofIslamicAzadUniversityofIzeh

Abstract
With regard to the scope of application of VCN 150 steel and the lack of a
coherentresearchandlaboratoryworkinrelationtothistypeofalloysteelgota
briefintroductiontothewaythistypeofalloysteelanditsscopeofoperationto
reviewthementionedlaboratoryandsimulationofit.Examplesinthelaboratory
procedureinaccordancewithtestmethodaccordingtothenumberofninepieces
of Taguchi outlines prepared and with Vf parameter (speed of progress), Vc
(rotationalspeed),ap(thedepthofthechip)tochecktheprocessofthevarious
conditions ofmilling machine. Finally, the surface roughness test for portable
devices by manufacturing parts model sutronic construction company taylor
hobsonandaccordingtotheoutputthatthedevicewasshowcased,moreprogress
inthespeedanddepthoftheshearsurfaceroughnesshasbeenmoreandmorebut
inthemethodofsimulationoftheAbaqussoftwaretoreviewandanalyzevarious
conditions and laboratory results and spent milling machine simulations we
comparedthepercentageerrorofthetwomethods.Athree-dimensionalfinite
elementmodelforsimulatingarealprocessofmillingmachinewasprovided.The
mostimportantfactorsinfluencingtheprocessofpelletwomannumericformand
examinethelaboratoryassembled.

Keywords: Millingparameters,Roughness,SteelVCN,Taguchitestingmethod,
simulation.

1
Introduction

Machining of a manufacturing process for shaping metal parts by removal of

excessmaterialfromthem.Eachpieceinthemachiningprocess,ontheonehand
must quality parameters such as surface finish machining accuracy and
dimensionaltoleranceandtheminimumcostofmachining,machiningtimeand
minimumormaximumprofittakenintoconsideration.isrequired.Theanalytical
models, due to limitations arising from quality parameters and machining
conditions, to meet criteria such as minimum cost of machining, minimizing
machiningtimehasbeendeveloped.

Toachievemaximumproductioncapabilityandpreciseacquirethepartgeometry
oftenusedmachiningprocess.Machiningofconversionprocessesthatremove
material from additional parts of the original piece, geometric shape that is
created. So it is defined removal of material with a sharp machining such as
turning,milling.

Varioustypesofmaterialsaremachinedshapesandgeometricfeaturessuchas
slotsscrews,precisionholes,edgesandpagescanbesolvedverypolishedand
smooth.Italsooptimizepartsfordimensionalaccuracyofcasting,formingand
shapingpossible.Thereasonsforusingmachiningcanreducethermaldistortion
anddiscolorationofpaymentmethods,reducingproductioncosts(usuallyinlow
numbers) and create features and surface textures to be named. More waste
generated,time-consumingprocess,massproductionmoreexpensiveandmore
energyisoneofthelimitationsofmachiningprocess.

Eachmachiningoperationsontwofactorsrelativemotionbetweentoolandwork
pieceandcuttingtoolgeometryinfluenceonthepartgeometrybythefruitingpart
geometry(feed)oracuttingtooloracombinationofthetwowhichdetermined.

Intraditional machining techniques, themachining parameters bydesigners or

manufacturersofmachinetoolandmachiningprocessbasedontheexperienceof
this group of professionals and also took handbook tools. This is usually
conservativeparameterswereusedbyordinarypeople.Coldingreportedthat40
percentgreaterthanthatoftheoptimalparametersusedintheprocess[2].

Bozlixandpartnerstoreviewtheircapacityandsurfacefinishonthemachined
surfaceswithdifferentshapes.Theytesteddifferentstrategiesandsurfacefinish
assessedinthiscase.Finally,theoptimalmodeforsurfacefinishachieved[3].

Bojilinandcolleaguestoreviewthestructureandsurfacefinishtheirfive-axis
millingwithchangesinshearrate.Theyaredifferentstrategiesformillingrough

2
surfaces(NonUniformRationalB-Spline)arepresentedanddiscussedtheirfinal
surfacefinish.Finally,theystatethatitwasthebestsurfacefinish,introduceand
analyze parameters it. Figure: 1 magnification of 100 micrometers in milled
surfacetopographyshowsfordifferentspeeds[4].

A B

Figure1:theshapeofthetopographyofthesurfacemillingmachinefortheshear
ratea)150m/min)300m/minc)450m/min.

Willeyetal.in2008toextractthemovetoolincomplexcurves.Itwasinitiallya
seriesofcircularandlinearlinestocurvesofnares.Thenitcurvessmoothlyand
intheendmovetooltonavigatethecurveswereextracted.Theresultsshowed
thatthismethodofprogressandmomentumswingsinthiscasehavedramatically
reducedcomparedtonormalmode[5].Muruganandassociatestoreviewchanges
totheroughnessofthesurfacebychangingtheparametersofmachining.With
Taguchi method tested and designed with the most optimal mode of genetic
algorithmforsurfaceroughnessphilanthropists.Theshapeofthetypicallevelof
carpictures22workwithshearspeed150m/minandtherateoftheadvanceof
04.0mmonadentintwoZoom200and1000timestheshow[6].

Hassanpourandpartnerstoexaminedifferentstrategiesofarbitraryshapealong
withlevelsofmillingmachinebychangingtheparametersofthemachinestested.
Thefinalresultsindicatethatitisworkingonthemachinestrategiesthefinal
workpiecepropertiessuchashardnessandsurfacesmoothnessisimportant[7].

3
 Snag

Pix

Bruise

B A

Figure2:imagestakenbytheelectronmicroscope,forexamplea:zoom
magnification200times1000times

ThesurfaceroughnesslevelsDASandcolleaguesintheprocessofturninghard
workinghardalloysteel,coatedbytoolwereexamined.Inthetesttheimpactof
threerateparameters,shearvelocityanddepthofprogresscuttingthecheckandit
becameclearthattherateofprogressandtheshearvelocitywerethemost
influenceonthesurfaceroughness.Figure23averageroughnesssurface
roughnessprofilesandequaltothecentrallinebetweenitandtheintegralof
.[absoluteroughnessprofileorduringthemeasurement[8

Averageline

4
Figure3:schematicformandhowtodeterminethemeanroughnesssurface
roughness

5
Moisanstudiesontheeffectsofshearrateandtherateofprogress,clickonthe
tool wear in turning on the hard level health gears hardened steel Mn5Cr27
topical.Theresultssuggestthattherateofprogresswasthemainparameteron
surfaceroughnessaffects[9].Lubricationusingtheminimumshearastheprocess
fluidiscompatiblewiththeenvironment,thewayinwhichasmallamountof
fluidinsidetheairjet,andplacetheslicessprinkled.Theuseofthesemethodsin
additiontoreducingtheintakeoffluidshear,drymachiningmethodrestrictions
removed,reducedfrictiontoformaneffectiveobaathreducingheatinthecutting
position.AlotofresearchonthemethodofMQLstablecoolingasareplacement
and lubrication in the process of machining has taken place [10]. Silva et al.
impactofthreedryenvironment,traditionalworkofMQLlubricantonsurface
roughnessandtoolwearrateofalloysteelAISI4340intheprocessofmilling
machinewereexamined.Figure3MQLdeviceusedtoperformtheexperiment
showsthe[11moisanstudiesontheeffectsofshearrateandtherateofprogress,
clickonthetoolwearinturningonthehardlevelhealthgearshardenedsteel
Mn5Cr27 topical. The results suggest that the rate of progress was the main
parameteronsurfaceroughnessaffects[9].Lubricationusingtheminimumshear
astheprocessfluidiscompatiblewiththeenvironment,thewayinwhichasmall
amountoffluidinsidetheairjet,andplacetheslicessprinkled.Theuseofthese
methodsinadditiontoreducingtheintakeoffluidshear,drymachiningmethod
restrictionsremoved,reducedfrictiontoformaneffectivereducingheatinthe
cutting position. Alotofresearchonthemethod ofMQLstablecooling as a
replacement andlubrication intheprocess ofmachining hastakenplace[10].
Silvaetal.impactofthreedryenvironment,traditionalworkofMQLlubricanton
surfaceroughnessandtoolwearrateofalloysteelAISI4340intheprocessof
milling machine wereexamined.Figure24MQLdevice usedtoperformthe
experimentshowsthe[11].Mopisanstudiesontheeffectsofshearrateandthe
rateofprogress,clickonthetoolwearinturningonthehardlevelhealthgears
hardenedsteelMn5Cr27topical.Theresultssuggestthattherateofprogresswas
the main parameter on surface roughness affects [9]. Lubrication using the
minimumshearastheprocessfluidiscompatiblewiththeenvironment,theway
inwhichasmallamountoffluidinsidetheairjetandplacetheslicessprinkled.
Theuseofthesemethodsinadditiontoreducingtheintakeoffluidshear,dry
machining method restrictions removed, reduced friction to form an effective
reducingheatinthecuttingposition.AlotofresearchonthemethodofMQL
stablecoolingasareplacementandlubricationintheprocessofmachininghas
takenplace[10].Silvaetal.impactofthreedryenvironment,traditionalworkof
MQLlubricantonsurfaceroughnessandtoolwearrateofalloysteelAISI4340in
theprocessofmillingmachinewereexamined.Figure24MQLdeviceusedto
performtheexperimentshowsthe[11].

6
 Figure4:theshapeofthedeviceusedtoperformtestMQL

Andthepartners,toexaminetheeffectoflubricationonsurfaceroughnessin
MQLmethodforsteelturning4340anditbecameclearthatusingthismethod
lowersthetemperatureofthecuttingareaandthusreducetheroughnessofthe
surface[12].Leo&Associates,toreviewthehealthattributesofsteelsurfaceGCr
withthehardnessofabout60Rockwellc.Theresultsshowedthat,undersome
circumstances,itispossibletoshearwastethereistensionstretching.Aswellas
thelevelofroughnessinturningpartswithahigherhardnessof50Rockwellc
reducedthermalbalanceofheatanddistributionpartnersintheworkpiecehole
deepintheprocessofworkingwiththeuseofhalf-drylubricationstudy.Itis
limitedtothecomponentsofaworkpieceandtemperaturedistributionanalysisof
apieceofworkduringtheprocessofpiercingthedeephole.Figure5milling
temperatureanalysisshows[14].

7
 Figure5:shapeanalysisofmillingtemperature

Tedslanandpartnersworkingwiththeholeprocessofliquidlubrication,dryand
half dry and wear the tools, how to form filings, force, torque and surface
roughnessobtainedinthisstudyare.Basedontheresultsoftheseresearchers,
lubricationinthecaseofdryandsemi-dryleadstolesstoolwear,whilesurface
roughnessobtainedwithmoredrylubrication modefromothermodes hosting
[15].Andcolleaguesconductedaseriesofexperimentstoinvestigatetheeffectof
lubrication andabrasion on the semi-arid roughness surface machining onthe
latheworkoperation.Basedonitsresults,withtheuseofthistypeoflubrication,
thesurfaceroughnessofmachiningandtoolwearduetothereductionofthe
temperatureoftheareaofmachining,reduced[16].Thesurfaceroughnesslevels
DASandcolleaguesintheprocessofturninghardalloy4340steelharderworkby
meansoftools,coatedexamined.Inthetesttheimpactofthreerateparameters,
shearvelocityanddepthofprogresscuttingthecheckanditbecameclearthatthe
rate ofprogressandtheshearvelocity, inorderofgreatest influenceontheir
surfaceroughness[17].Regressionequations forthefrequencyofapplications
models.

Datasimulationanalysisofmillingmachineinthissectionabouthowmodeling
andcorrectnessofthepresentedmodelswillbediscussed.Inaccordancewiththe
issuetermstheconditionsofsimulatedlaboratoryforalltheparametersaffecting
theprocessofmillingmachine.Effectiverotationalparameterspresentinthe

8
workloadtoolspeed,linespeedandmotionvectortimesthedepth.Withseven
differentsimulationcanbetheeffectofalltheseparametersonsurfaceroughness
ofview.ThedifferentmodesisshowninFigure6.

Figure6:parametersaffectingtheprocessofmillingmachine

Threedimensionalsimulationmodelingistheprocessofmillingmachineusing
ABAQUS/Explicit6.10.1software.NumberofvectorbasedonISOfilingstools
equal DNMG 11 04 08-1125 SF. Schematic view of the diamond and its
dimensionsandshapeinFigure7,8isshown.

Figure7:schematicviewofthediamond

9
 Figure8:Diamonddimensionsareinmm.

Figur9:viewofgeometryandpartitioningtools

Rigidtoolsofthetypedefinedinthesoftware.Geometryandpackagingtoolinthe
formofasizeable.Elastic-plasticmaterialmodelwithhardforexample,the
definitionof.Thermaleffectsofregardless.Forthisreasonthattherateof
coolingpiecesintheveryact.Figure4,6geometryandpackagingshowsasample
Atotalof18diamondsinaccordancewiththeconditionsoftheexperiments
onthecircularradiusoftheenvironmentalAssembly,accordingtofigure8,93cm
betweentheprojectileandthelevelofcontactwiththesurfaceofthesamplesnode
contactpenaltyalgorithmwasused.Theleveloftheexistingnodesandallthe
diamondsinthehighlevelinstanceshavethepossibilityofmakingcalls.Hence
,wasdefinedforthem.Boundaryconditionsandtheloadappliedtothesamplesand
toolsinaccordancewithFigure.Thetypicalelementsofanodewithabricktype
eight-pointandintegralcontrol(C3D8R)andtheelementsoftherigidelementsof
thediamondtype(R3D4).Figure8andfigure9
showsexamples.howtomeshlayoutelements.

10
Figure10:viewofgeometryandpartitioningexample

Figure11:viewofassemblingthediamond

11
Figure12:boundaryconditionsandloadthesampletoolandchip(V=rotational
speedandlinearspeed=VR)

Figure13:somehowsupplydiamonds

Figure14:somehowtypicalpackagingelements

ContourMisesequationstensionatthebeginning,middleandendoftheprocessis
showninFigure15millingmachine.Also,theexamplesandtheisolatedelements
afterthecompletionoftheprocessisshowninFigure16.

12
Figure15:Misesequationsduringtheprocessofstresscontourmillingmachine
(a:b:thebeginningoftheprocess,inthemiddleoftheprocessandtheendofthe
process:c)

Figure16:aviewofthesampleandoftheisolatedelements

Calculationofroughnessparametershereitisnecessarytodefinetheparameters
of roughness. The main objective of this study was to investigate, because
differentconditionsonsurfaceroughnessofmillingmachine.Surfaceroughness
generallyresultfromthemanufacturingprocessorthetermsofthearticle.The
mostimportantparameterforroughnessparametersoftendescribethetopography

13
ofthesurface.Theseparametersusingtheverticaldisplacementonthesurfacecan
be defined. According to the standard ISO 4287 roughness parameters are of
averageheight,RaRqRtChisumofsquaresofmaximumheightandroughness,
subtracting the minimum measured along the route. These parameters are
calculatedbythefollowingrelations.Calculationofroughnessparametershereit
isnecessarytodefinetheparametersofroughness.Themainobjectiveofthis
studywas toinvestigate, because different conditions onsurface roughness of
milling machine. Surface roughness generally result from the manufacturing
processorthetermsofthearticle.Themostimportantparameterforroughness
parametersoftendescribethetopographyofthesurface.Theseparametersusing
theverticaldisplacementonthesurfacecanbedefined.Accordingtothestandard
ISO 4287 roughness parameters are of average height, Ra Rq Rt Chi sum of
squaresofmaximumheightandroughness,subtractingtheminimummeasured
alongtheroute.
These parameters are calculated by the following relations.Calculation of
roughnessparametershereitisnecessarytodefinetheparametersofroughness.
Themainobjectiveofthisstudywastoinvestigate,becausedifferentconditions
onsurfaceroughnessofmillingmachine.Surfaceroughnessgenerallyresultfrom
the manufacturing process or the terms of the article. The most important
parameterforroughnessparametersoftendescribethetopographyofthesurface.
Theseparametersusingtheverticaldisplacementonthesurfacecanbedefined.
AccordingtothestandardISO4287roughnessparametersareofaverageheight,
RaRqRtChisumofsquaresofmaximumheightandroughness,subtractingthe
minimum measured along the route. These parameters are calculated by the
followingrelations.

14
3

1
5
That'sit,i'vespotheighty_itrackmeasuringheight.Roughnessparametersfor
thedifferentmodesusingtheverticaldisplacementofthespecifiednodesonthe
surfaceismeasured.First,youneedasourceforeachlinethepathtobesetina
waythatthetotalareaofthetopandbottomofthislinewiththecurveequals
zero. Then, the height ofall points of origin on the basis of this line can be
corrected.Finallyusingtherelationships(1)as(3)measurableparametersof
roughness. The parameters for the three different track that is similar to the
laboratory measurement of the model components were limited . The final
roughnessparameters ofroughnessparameters measuredintheaverageofthe
threeroutewascalculated.

Figure 17 roughness: paths

Check to ensure the accuracy of the energy model for analysis of model
components, when the pseudo stability processes using explicit halgar will be
analysis,shallbeapplicabletotheinternalenergyofthekineticenergy.Thisratio
must always be less than 10%, otherwise the answer is not enough accuracy
obtained.Theseconditionsforallthesamples.Figure18internalenergychanges
tokineticenergyratioaccordingtothetimeoftheshow.

16
Figure18: energy changes to kinetic energy inside during the process of
milling machine in the sample

Theconvergenceofelementstocheckconvergenceconditionsforthemeshmodel
millingmachineN=250,28=Vandmm5/1=awereconsidered.Samplelevel
equaltoequalheightandmm4mm4mm10.Thesizeoftheelementsatahigh
leveloverthecourseof5stepstoreducethesampleanswersconverge,Figure19.
Theselectedsizeisequalto500,400,300and250m.Convergenceresultsfor
thedifferentparametersofroughnessintheshapeof416.Ascanbeobserved,the
slightchangestotheparametersofroughnessforsmallersizeoffourmicrons.
Thereforeitcanbeconcludedonthe300Micronsizeanswersconverge.

17
 Figure19:changethesizeoftheareaelements

Figure20: changes the parameters of roughness according to the size of the

elements

getthepropersizeelementsshouldalsoreviewthethegeometryaftereffect
samplesize.Therefore,inordertoscratchtherightheightformodelafterafew
specificsimulation.Then,threedifferentsizeswereconsideredforthesurfaceof
thesample.TheeffectofchangingthegeometricdimensionsinFigure418.Itis
knownthatasignificantchangeasaresultofchangesintheparametersofsurface
roughnessdimensionswillnotbeviewing.Therefore,thevalueforthelevelof
.sample4mm4mm

18
 Figure21:threedifferentsampledimensions

Figure22: effect of roughness parameters on geometry

19
 Theconclusions
inthisstudyacomprehensivereviewfortheeffectofdifferentparameterson
thesurfaceroughnessofthesamplesaftertheprocessofmillingmachineby
testingandsimulation.
Inthecaseofthenumericalresultsandtheexperimentalmeasurementswas
discussed.
The ability of the model components are presented in the limited case of
differenteffectsontheforecastsexaminethevaluesshown.
Onthisbasis,thefollowingconclusionscanbestated:athree-dimensional
finite element modelforsimulating arealprocessofmilling machine was
provided. Results of laboratory measurements of roughness surface with
numericalresultsverygoodmatchshowedthattheaccuracyandcapabilityof
afiniteelementmodelpresentedinthisstudysuggest.
Themostimportantinfluencefactorsonprocessofpelletwomannumericand
laboratorytobeexamined.Basedontheresultsitbecameclearthatwiththe
increaseinrotationalspeedoftoolsreducedroughnessparameters.
Thedecreaseinthespeedoftheprogressofthequalitylevelofthesampleafter
processwillincreasemillingmachine.
Roughnessofthesurfacewiththeincreaseintherateoffilingstakinganotable
increase.

The following suggestions can be used to improve and continue the research
proposal:

the effect of different milling machine tools, check the waste created tension
arising from the process of milling machine for experimental and numerical
investigationoftheeffectofcrystalstructureonthemillingmachineandhard
surfaceofthesampleindifferentconditionsimpactingonthelifeofthemilling
machineparts,fatigueandstressonthethermaleffectofroughnessinfluencethe
final processes of waste samples, such as grinding, polishing after milling
machine

20
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