engleski

Influence of cutting parameters on cutting forces and surface roughness in milling of aluminum foam

Metal foams present a new form of porous materials with a unique combination of light weight and good mechanical properties. Such materials have already been implemented in a myriad of high-tech industries such as aerospace, automotive and biomedicine. The main focus of this paper is to determine the influence of cutting speed, vc and feed per tooth, ft on cutting forces and surface roughness of closed cell aluminum alloy, A380 foam. Cutting force measurements were conducted using a multi-component dynamometer. Both cutting force components, Fx and Fy increased as feed per tooth increased. Increasing cutting speed led to a lower value of Fx cutting force component. The value of Fy cutting force component initially decreased with an increase in cutting speed. An increase in Fy cutting force component was observed at high cutting speeds and low feed per tooth. An optical profilometer which is used for quantifying the surface roughness provides non- contact 3D texture measurements. Test results show that increasing feed per tooth leads to a drastic increase in surface roughness of the cell walls while increasing cutting speed produces a lower surface roughness. Using the test results, regression models were generated that allow for accurate prediction of Sa, Fx and Fy variables based on input cutting parameters.

Closed cell aluminum foam ; Profilometer ; Milling ; Surface roughness ; Cutting Fforces

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