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 Study of Burr Size and Surface Roughness in High Speed Face Milling

 Amit Bansal and Kiha Lee 

Sponsored By: CODEF 

Abstract 

Due to rapid growth and competitiveness of the automobile industry, reduction in total machining time has become a basic necessity and many industries are switching to high speed machining. This study presents the results of tests done with a high speed face-milling machine tool at Daimler-Chrysler, Germany. Experiments were performed on four different materials for various combinations of tool geometries (rake and lead angles) and cutting parameters (speed, feed rate and depth of cut). A substantial amount of experimental data was collected regarding the burr formation and surface roughness for aluminum and magnesium alloys. A software tool for theoretical exit order sequence (EOS) prediction was also developed in JAVA for verifying the experimental results.

Keywords: Aluminum, burr formation, exit order sequence, high-speed face milling, magnesium. 

 

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