Eventos Anais de eventos
COBEM 2021
26th International Congress of Mechanical Engineering
EFFECT OF MACHINING PARAMETERS ON CUTTING FORCES DURING THE END MILLING OF UNS S32205
Submission Author:
Julia Canicali , RS
Co-Authors:
Julia Canicali, Eduardo Sperotto, Mauricio R. Policena, André João de Souza
Presenter: Julia Canicali
doi://10.26678/ABCM.COBEM2021.COB2021-0115
Abstract
Duplex stainless steel (DSS) is a low-machinability alloy applied in oil tanker tanks, pulp and paper industry, digesters, valves, flanges, and pipes. DSS alloy is formed by a biphasic structure composed of about 50% ferrite and 50% austenite; hence, grains of different hardness coexist side by side. The tool will alternate cutting between soft and hard grains, tending to initiate a self-excited vibration during the machining. Moreover, a greater cutting force in the feed direction is produced on DSS machining due to its lower ductility and high tensile strength at high temperatures. Thus, it is intended to investigate the influence of machining parameters [spindle speed (n), feed per tooth (fz), axial depth of cut (ap), and tool nose radius (r)] on the static (µF) and dynamic (ΔF) elements of the active (Fa) and passive (Fp) machining force components generated by wet end milling of UNS S32205. The response variables (µFa, ΔFa, µFp, ΔFp) will be analyzed through the Box-Behnken design of experiments, and it will allow a detailed evaluation of the effects caused by the controllable factors (n, ap, fz, r). It is supposed that the cutting parameters will affect the response variables differently during the DSS milling. It is well-known that the cutting parameters "fz" and "ap" influence significantly the machining force components. When analyzing the static forces, lower "fz" and "ap" levels (smaller cutting section) will probably reduce the active force to lower "n" levels. Previous studies showed that the increment of "n" combined with larger cutting sections (higher "fz" and "ap" levels) increased the passive force. When "ΔFa" > "μFa", the cutting process is being carried out in an unstable regime, damaging the texture of the material's machined surface. This information is extremely relevant because surface quality is indispensable when the material is exposed to corrosive environments. Regarding the dynamic elements of the active and passive forces, it is presumed that the increase in the spindle speed will influence the cutting stability. The influence of the penetration rate (ap/r ) in DSS milling is still unclear. Thereby, it is expected to demonstrate that the larger the tool nose radius, the greater the influence on passive force and milling process stability.
Keywords
duplex stainless steel, End milling, active and passive force components, static and dynamic forces, Box-Behnken Design
