This thesis presents the research work carried out in an experimental study on High Speed Milling and a predictive force model. The Oxley??s machining theory [36] that can be considered a purely theoretical approach, which has not yet been applied to the high speed milling process is used to model this process in order to predict the cutting forces. An experimental programme was carried out in order to study and understand the high speed milling process and to collect force data for machining of AISI 1020 plain carbon steel at speeds from 250 to 500m/min, feed rates 0.025 to 0.075mm/tooth and 0.5 and 0.8mm depths of cut, using three different tool configurations with different nose radii. The model developed by Young [5] using the Oxley??s machining theory, for conventional milling, was first applied to the high speed milling operation. The force predictions were satisfactory compared to the measured forces. Using this as the basis, a theoretical model was developed to predict the cutting forces in high speed milling. A smaller chip element was considered in applying the machining theory to satisfy the assumption of two dimensional deformation in the machining theory. Using the flow stress properties for plain carbon steels obtained by Oxley and his co-workers, the cutting force components: tangential, radial and vertical, were predicted with the new developed model for AISI 1020 steel for the same cutting conditions used in the experiment. The model was able to accurately predict the tangential force, while the other two components showed a good agreement with the experimental forces. Then the model was verified using two other materials namely, AISI 1045 plain carbon steel and AISI 4140 alloy steel. The alloy steel was used in both the states, virgin and hardened (heat treated) for the experiment. The comparison of predictions with experimental forces showed good results for these additional two materials. From the results obtained, it is concluded that the developed model can be used to predict the tangential cutting force accurately, while predicting the other force components with a favourable accuracy.
| Identifer | oai:union.ndltd.org:ADTP/282285 |
| Date | January 2010 |
| Creators | Ekanayake, Risheeka Ayomi, Mechanical & Manufacturing Engineering, Faculty of Engineering, UNSW |
| Publisher | Awarded By:University of New South Wales. Mechanical & Manufacturing Engineering |
| Source Sets | Australiasian Digital Theses Program |
| Language | English |
| Detected Language | English |
| Rights | http://unsworks.unsw.edu.au/copyright, http://unsworks.unsw.edu.au/copyright |
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