Applications of high speed machining in the industry

Variants of high speed machining
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is a method that allows us to reduce the production time and enhance the surface quality of the machined pieces. HSM is primarily employed in three industries because of its unique demands.
The first ones of these are industries that require the processing of aluminum alloys for the production of automotive parts, medical devices, or small computer parts
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. The earlier-mentioned industrial sector requires the quick removal of metal, as the technological process includes a lot of processing processes. Recent studies on this subject have been summarized as follows.
In the study by Jomaa et al.
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, AA and AA aluminum alloys that are commonly utilized in automotive and aerospace industries were studied experimentally and numerically by focusing on chip formation and residual stresses under identical HSM conditions. The results showed that each of the alloys examined showed various mechanisms of chip formation and residual stress conditions on the treated surfaces. On the contrary, it is observed that the AA alloy continuously produces shavings and stress residual stresses, whereas the AA alloy generates broken chips and compressive residual stresses. The results of the FEM analysis suggest that the AA alloy produces a lower cutting temperature at the tool/chip interface, with higher equivalent total strains change on the surface machined than the AA alloy. According to numerical and experimental findings, initial yield stress and thermal conductivity were found to be the main reasons for the difference.
Bardetsky et al. conducted experimental studies for the purpose of determining the impact of cutting conditions (cutting speed, feed, and cutting depth) and time change of carbide tool wear data on cutting conditions of Al-Si casting alloys at HSM (face milling. These Al-Si casting alloys are widely utilized in the automotive sector. The resulting test findings were employed for calibrating and validating the developed tool wear pattern based on fracture mechanics. It has been demonstrated that the model needs only four experimental points for calibration and predicts tool wear in an accurate way under various cutting conditions. The model was confirmed as a result of comparing experimental tool wear data with the estimated tool wear with the calibrated model. Verification outcomes show that the suitability of the tool wear is excellent. It is stated that the maximum error is less than 7% In the study by Ng et al.
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, advanced production technology of high- silicon aluminum alloys is among the production methods needed for acquiring the necessary enhancements for vehicles of the new generation. In the course of ultraHSM of aluminum alloys, machined part/piece surface integrity, part distortion, and burr formation control the most suitable machining parameters and tool geometry. A dual approach including both experimental and theoretical (modeling) studies was applied to the research objectives presented in the current research. High speed processing was used at 5000 m/min. The most significant factors related to tool life and wear mechanisms from the experimental analysis are the microstructure and inhomogeneities of the workpiece material, silicon content, and nonmetallic inclusions. The finite element analysis

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