Tool Monitoring – A Scalable Learning Approach to Estimate Cutting Tool Conditions with Machine-Internal Data in Job Shop Production of a Milling Process

Modeling the milling process requires cutter/workpiece engagement (CWE) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. This geometry defines the instantaneous intersection boundary between the cutting tool and the in-process workpiece at each location along a tool path. This paper presents components of a robust and efficient geometric modeling methodology for finding CWEs generated during 3-axis machining of surfaces using a range of different types of cutting tool geometries. A mapping technique has been developed that transforms a polyhedral model of the removal volume from Euclidean space to a parametric space defined by location along the tool path, engagement angle and the depth-of-cut. As a result, intersection operations are reduced to first order plane-plane intersections. This approach reduces the complexity of the cutter/workpiece intersections and also eliminates robustness problems found in standard polyhedral modeling and improves accuracy over the Z-buffer technique. The CWEs extracted from this method are used as input to a force prediction model that determines the cutting forces experienced during the milling operation. The reported method has been implemented and tested using a combination of commercial applications. This paper highlights ongoing collaborative research into developing a Virtual Machining System.

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Analytical Calculation of Cutter/Workpiece Engagements for Helical Hole Milling

Volume 2: 29th Computers and Information in Engineering Conference, Parts A and B ◽

10.1115/detc2009-86221 ◽

2009 ◽

Cited By ~ 3

Author(s):

Jue Wang ◽

Derek Yip-Hoi

Keyword(s):

High Speed ◽

Cutting Tool ◽

Analytical Calculation ◽

Milling Process ◽

Helical Milling ◽

Helicoidal Surface ◽

Swept Volume ◽

Intersection Geometry ◽

Intersection Curves ◽

Solid Modeler

Helical milling is a 3-axis machining operation where a cutting tool is feed along a helix. This operation is used in ramp-in and ramp-out moves when the cutting tool first engages the workpiece, for contouring and for hole machining. It is increasingly finding application as a means for roughing large amounts of material during high speed machining. Simulating the helical milling process requires Cutter/Workpiece Engagement (CWE) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. For hole milling an additional complication comes from self-intersections that occur with the tool swept volume. This makes the generation of the instantaneous in-process workpiece needed for finding the CWE difficult. In this paper we present an analytical approach for finding the engagement geometry that utilizes the intersection curves between a cylinder representing a flat end mill and the helicoidal surface generated by the bottom of the tool as it feeds downwards along the helix. This technique can be integrated into a solid modeler based approach for machining simulation. It has the advantage of not require instantaneous updates of the workpiece as is typically the case in finding CWEs.

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Cutting Tool Geometry for Plunge Milling–Process Optimization for a Stainless Steel

Procedia CIRP ◽

10.1016/j.procir.2012.04.090 ◽

2012 ◽

Vol 1 ◽

pp. 506-511 ◽

Cited By ~ 12

Author(s):

Martin Witty ◽

Thomas Bergs ◽

Alexander Schäfer ◽

Gustavo Cabral

Keyword(s):

Stainless Steel ◽

Process Optimization ◽

Cutting Tool ◽

Milling Process ◽

Tool Geometry ◽

Plunge Milling

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Study on Path Planning of Involute Tooth Surface Milling With General Cutting Tool

Volume 10: 2019 International Power Transmission and Gearing Conference ◽

10.1115/detc2019-97156 ◽

2019 ◽

Author(s):

Zhaoyao Shi ◽

Zhipeng Feng ◽

Peng Wang

Keyword(s):

Tool Path ◽

Cutting Tool ◽

Market Competition ◽

Cutting Tools ◽

Difficult Problem ◽

Milling Process ◽

Tooth Surface ◽

Involute Gear ◽

Accurate Position ◽

Cutting Path

Abstract Milling involute tooth surface with universal cutting tool overcomes the difficult problem of customizing tool for nonstandard gear machining. It is difficult for gear manufacturers to gain an advantage in market competition because of the long cycle of customized cutting tools. In this paper, the milling path of involute tooth surface by a general cutting tool is studied, and how to obtain the uniform surface roughness of involute tooth surface and the cutting path scheme of cutting tool is discussed. The key point of this paper is to put forward the scheme of tool path in the milling process. The end profile of involute gear is modeled by an analytic method, and the equidistant contour of the profile of involute gear is established by using the principle of normal deviation, which provides an accurate position point for the cutting tool.

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Research and Optimization of Surface Roughness in Milling of SLM Semi-Finished Parts Manufactured by Using the Different Laser Scanning Speed

Materials ◽

10.3390/ma13010009 ◽

2019 ◽

Vol 13 (1) ◽

pp. 9 ◽

Cited By ~ 2

Author(s):

Andrzej Matras

Keyword(s):

Surface Roughness ◽

Feed Rate ◽

Laser Scanning ◽

Cutting Tool ◽

Scanning Speed ◽

Milling Process ◽

Face Milling ◽

Machining Parameters ◽

The Face ◽

Laser Scanning Speed

The paper studies the potential to improve the surface roughness in parts manufactured in the Selective Laser Melting (SLM) process by using additional milling. The studied process was machining of samples made of the AlSi10Mg alloy powder. The simultaneous impacts of the laser scanning speed of the SLM process and the machining parameters of the milling process (such as the feed rate and milling width) on the surface roughness were analyzed. A mathematical model was created as a basis for optimizing the parameters of the studied processes and for selecting the sets of optimum solutions. As a result of the research, surface with low roughness (Ra = 0.14 μm, Rz = 1.1 μm) was obtained after the face milling. The performed milling allowed to reduce more than 20-fold the roughness of the SLM sample surfaces. The feed rate and the cutting width increase resulted in the surface roughness deterioration. Some milled surfaces were damaged by the chip adjoining to the rake face of the cutting tool back tooth.

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