Abstract
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•An experimental study on specimens based on L27 Taguchi design was conducted.•An empirical model of the cutting force grouping tool stiffness and cutting parameters was built.•Influence of the cutting parameters on tool deflection, tracking errors and roughness is carried out.•Sensitivity of the cutting parameters on the machining process of gas turbine blades.
In mechanical manufacturing, parts containing complex surfaces are extensively used to meet specific necessities such as performance, appearance and lightweight. However, dimensional and geometric non-conformities related to the cutting parameters were found.
Thus, the aim of this paper is to introduce an experimental study conducted on workpieces obtained from AISI 304 stainless steel to control the milling process in terms of tool deflection, tracking error and surface roughness. To achieve this objective, a 3-axis CNC machine and an end-ball tool were used to manufacture the work pieces. The shape and dimensions of each specimen were inspired from the components of gas turbine blades containing complex shapes. A L27 Taguchi standard was adopted as a Design of Experiment (DOE) grouping three factors (cutting speed, feed speed, axial depth) with three levels.
The obtained results show how much the tool deflection and the tracking errors are mainly influenced by the feed speed and the cutting speed.
Combining experimental and analytical models, an empirical model of the cutting force perpendicular to the tool axis, grouping tool stiffness and cutting parameters, is proposed in this study. The increase of the axial depth conduces to an increase in tool deflection, the tracking errors and the cutting force.