Analysis of Force, Temperature, and Surface Roughness during End Milling of Green Composites

ABSTRACT

The use of biodegradable or green composites has been increasing exponentially due to the growing environmental concern. Though these composites are fabricated to near-neat shape but milling is an unavoidable machining operation that is required for removing undesired material to meet the design necessities. In this study, the milling behavior of green composites (polylactic acid/bamboo) fabricated using compression molding has been extensively studied by investigating the induced forces, temperature, and surface roughness. The process parameters of milling operation such as spindle speed (500, 710, 1400, and 2000 RPM), feed rate (80, 112, 160, and 224 mm/min), depth of cut (0.5, 1, 1.5, and 2 mm), and milling cutters (slot and end mill cutters) have been optimized through Taguchi analysis for obtaining minimum milling-induced forces, temperature, and surface roughness. The relative significance of each process parameter has also been found through the analysis of variance. Milling cutter and depth of cut are the two parameters found to have significant contributions in determining the quality of the milling surface. Lower milling-induced force, temperature, and surface roughness can be obtained by selecting a lower depth of cut and end mill cutter during the milling of green composites.

摘要

随着人们对环境问题的日益关注，可生物降解或绿色复合材料的使用呈指数级增长. 虽然这些复合材料被加工成近乎整齐的形状，但铣削是一种不可避免的加工操作，需要去除不需要的材料以满足设计的需要. 在这项研究中，通过研究诱导力温度和表面粗糙度，广泛研究了用模压法制备的绿色复合材料（聚乳酸/竹子）的铣削行为. 通过田口分析优化了铣削操作的工艺参数，如主轴转速（500、710、1400和2000 RPM）、进给速度（80、112、160和224mm/min）、切削深度（0.5、1、1.5和2mm）和铣刀（槽铣刀和端铣刀），以获得最小的铣削诱导力、温度和，表面粗糙度. 通过方差分析，找出了各工艺参数的相对显著性. 铣刀和切削深度是决定铣削表面质量的两个重要参数. 在铣削绿色复合材料时，通过选择较低的切削深度和端铣刀，可以获得较低的铣削力、温度和表面粗糙度.

KEYWORDS:

• Green composites
• milling
• forces
• temperature
• surface roughness
• Taguchi analysis
• 关键词:;绿色复合材料
• 铣削力
• 军队
• 温度
• 表面粗糙度
• 田口分析