Investigation on cutting parameter models and processability index in 3D marble products with milled tools

• Published in: Arabian journal of geosciences 2021-09, Vol.14 (18), Article 1854
• Main Author: Gencay, Sarıışık
• Format: Article
• Language: English
• Subjects: Chemical properties; Chemicophysical properties; Clustering; Cutting; Cutting energy; Cutting force; Cutting parameters; Diameters; Earth and Environmental Science; Earth science; Earth Sciences; Empirical analysis; End milling cutters; Feed rate; Feeds; Marble; Mathematical models; Mechanical properties; Natural stone; Numerical controls; Original Paper; Parameters; Physical properties; Process parameters; Regression analysis; Statistical analysis; Statistics
• ISSN: 1866-7511; 1866-7538
• DOI: 10.1007/s12517-021-08256-z

In this article, cutting parameter models ( F c , F t , and E c ) and the processability index in the processing of 3D marble products with a milled tool with a computer numerical control (CNC) machine are examined. For the experimental studies, seven types of natural stones, 4.0-mm-diameter end mill set, thirteen different cutting depths ( d p ) between 0.1 and 2.0 mm, and 5 different feed rate ( V a ) parameters between 2000 and 4000 mm/min were selected. Chemical properties, mineralogical and petrographic properties (thin section with polarized microscope, XRD, and SEM analysis), and the physical and mechanical properties of marbles were determined. F c and F t experiments resulting from the processing of natural stone using a milled tool on a CNC machine were carried out. The relationship between the F c , F t , and E c parameters and physico-mechanical properties was analyzed statistically. The effects of F c , F t , and E c on equivalent chip thickness ( h eq ) and material removal rates (MRR) according to feed speeds were modeled. After that, the effect of physico-mechanical properties on F c , F t , and E c parameters are investigated based on the regression analysis, and the relations are statically modeled. Processability index of the 3D marble products was determined by the statistical K means clustering (KMC) method. Results indicate that depth of cut (0.1–2.0 mm) and feed speed (2000–4000 mm/min) are important cutting parameters in the processability of rocks. Empirical models have been developed to estimate the variation of cutting forces ( F c , F t ) and cutting energy ( E c ) with MRR and h eq values relative to feed speeds ( V a ). These models optimize the MRR and h eq values of tool composition and cutting process parameters. According to the statistical results, 3D marble products were classified according to the processability index depending on their F c , F t , and E c values.