Machining a through hole in a Bi-Metallic

plate of Stainless-Steel and Mild-Steel using

Helical Milling Technique
Introduction
Helical milling is an alternative hole-making machining process which presents several
advantages when compared to conventional drilling. In the helical milling process, the tool
proceeds a helical path while rotates around its own axis. Due to its flexible kinematics, low
cutting forces, tool wear, and improved borehole quality may be achieved [1].

Cutting Parameters [2]

Cutting forces
The cutting forces arising in machining metals are
considered. The mechanisms of chip formation and
material damage in the orthogonal cutting of
unidirectional composites are recalled; the trends
of cutting forces as functions of the operating
parameters, as highlighted by the experimental
results available, are illustrated; a number of
schemes for interpreting the cutting forces, taking into
account or disregarding the tool flank action, are
presented; and a number of analytical and numerical
models, put forward in the literature, are critically
reviewed. The topic of forces developing in drilling and milling, two of the most important
machining operations in composite industry, is then examined. Here, certain tendencies
identifying the main parameters affecting the cutting forces are discussed, along with models
that aim to predict the cutting forces depending on tool geometry.

Cutting edge radius and wear effect

When hard metals are machined, due to the cutting edge radius and its fast wearing, it is usual
that uncut chip thickness was below the minimum chip thickness (hlim), so no chip is formed,
predominating the ploughing condition. In this study, the minimum chip thickness is assumed to
be a fixed ratio (45%) of the cutting edge radius.

Honing-in Performance
During the cutting of ceramics, constant cutting conditions are often impossible to achieve.
The honing process is characterized by a honing-in behavior of the honing stones. The initially
sharp cutting grains blunt with increasing machining time, which consequently leads to a
decreasing material removal rate. Depending on the machined material and the implemented
honing stone specification, constant cutting conditions appear after a certain time; the honing
stones operate in the self-sharpening range, or they lose their cutting ability until no further
removal can be reached and the stones must be sharpened.

Cutting Temperature Models for Machining Processes

Cutting temperature is another important factor in HSM operations, and it plays a major role in
tool wear, tool life, and surface quality. Therefore, it is necessary to establish theoretical models
to accurately predict cutting temperature and then optimize machining parameters. Many
research efforts have been made to study the temperature and its distribution in the cutting
region.
Lazoglu and Altintas proposed a numerical model based on the finite difference method to
predict the steady-state tool and chip temperature fields as well as transient temperature
variation in continuous and interrupted orthogonal machining processes. Their approach can be
utilized to select the optimal cutting speed, feed rate, as well as tool geometries such as tool
rake and clearance angles so as to avoid excessive thermal loading of the tool. Ng et al. used
an FE model using FORGE2 to simulate cutting force and temperature distributions, and they
performed experimental tests at 20 000 rpm on an HSM center to verify the estimated
temperature. In their study, cutting temperatures were measured using thermocouple and
infrared techniques. Based on the comparative study, it was concluded that cutting
temperature is increased with the cutting speed and no reduction in cutting temperature was
observed when cutting speed increased. This result shows opposite phenomena to Salomon's
theory. The authors proposed a new methodology to the temperature prediction of milling. The
temperature of the work piece, during the milling operation, has been measured using
an infrared camera. During the experiments, cutting speed and feed rate have been changed.
After data analysis, an FEM model of the cutting process during milling was developed. The
rheological model is calibrated using different milling tests. The results of the model have been
compared with the experimental data, obtaining a good agreement. The approach can be useful
to the insert tool designer in order to improve the cutting tool performance.

Design of Experiment
We used Autodesk Fusion360 for our simulation of CAM program. We aligned the two plates
and used the optimum parameters provided by the software.

Cutting Parameters Feed Rate: 100

Spindle Speed: 2000 rpms
End Mill Cutting Tool Diameter 8 mm
Work Piece Dimension:
Mild Steel Thickness: 6mm
Stainless Steel Thickness: 11mm
The top material (shown by Red arrow) is Mild Steel and the below material
(shown by Yellow arrow) is Stainless Steel

Stainless Steel
Stainless steel is not a single material but the name for a family of corrosion resistant steels.
Like many scientific discoveries the origins of stainless steel lies in a serendipitous accident. In
1913 Sheffield, England, Harry Brearley was investigating the development of new steel alloys
for use in gun barrels. He noticed that some of his samples didn’t rust and were difficult to etch.
These alloys contained around 13% chromium.
The first application of these steels was in cutlery for which Sheffield subsequently became
world famous. Simultaneous work in France led to the development of the first austenitic
stainless steel.

Mild Steel
Steel is made up of carbon and iron, with much more iron than carbon. In fact, at the most, steel
can have about 2.1 percent carbon. Mild steel is one of the most commonly used construction
materials. It is very strong and can be made from readily available natural materials. It is known
as mild steel because of its relatively low carbon content.
Mild steel is very strong due to the low amount of carbon it contains. In materials science,
strength is a complicated term. Mild steel has a high resistance to breakage. Mild steel, as
opposed to higher carbon steels, is quite malleable, even when cold. This means it has high
tensile and impact strength. Higher carbon steels usually shatter or crack under stress, while
mild steel bends or deforms.
CNC Milling Center
Hole Made via Helical Milling of 10 mm Diameter
References
[1]: Bruno Dutra Pereira, Robson & Brandão, Lincoln & Paulo de Paiva, Anderson & Ferreira,
João & Davim, J. (2017). A review of helical milling process. International Journal of Machine
Tools and Manufacture. 120. 10.1016/j.ijmachtools.2017.05.002.
[2]: Z.Wang, M.Rahman. High-Speed Machining. Comprehensive Materials Processing
Volume 11, 2014.