Development of a feed rate adaption control system for high-speed rough and finish end-milling of hardened EN24 steel

Micro end milling is one of the most important micromachining process and widely used for producing miniaturized components with high accuracy and surface finish. This paper present the influence of three micro end milling process parameters; spindle speed, feed rate, and depth of cut on surface roughness (Ra) and material removal rate (MRR). The machining was performed using multi-process micro machine tools (DT-110 Mikrotools Inc., Singapore) with poly methyl methacrylate (PMMA) as the workpiece and tungsten carbide as its tool. To develop the mathematical model for the responses in high speed micro end milling machining, Taguchi design has been used to design the experiment by using the orthogonal array of three levels L18 (21×37). The developed models were used for multiple response optimizations by desirability function approach to obtain minimum Ra and maximum MRR. The optimized values of Ra and MRR were 128.24 nm, and 0.0463 mg/min, respectively obtained at spindle speed of 30000 rpm, feed rate of 2.65 mm/min, and depth of cut of 40 μm. The analysis of variance revealed that spindle speeds are the most influential parameters on Ra. The optimization of MRR is mostly influence by feed rate. Keywords:Micromilling,surfaceroughness,MRR,PMMA

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Investigation of Heat Assisted High Speed End Milling of Soda Lime Glass for Surface Generation

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.740.145 ◽

2017 ◽

Vol 740 ◽

pp. 145-151

Author(s):

Mohamed Konneh ◽

Mst. Nasima Bagum ◽

A.K.M. Nurul Amin ◽

Amira Fatin Asyah

Keyword(s):

Surface Finish ◽

Feed Rate ◽

High Speed ◽

End Milling ◽

Heating Temperature ◽

Soda Lime ◽

Surface Generation ◽

Quadratic Model ◽

Depth Of Cut ◽

Soda Lime Glass

Brittle materials like soda lime glass can be machined in ductile mode under controlled machining conditions (feed rate, depth of cut, small tool edge radius) using high speed to generate a desired surface finish. The heat generated in high speed machining tends to promote ductile machining. In this paper, heat assisted high speed end milling is investigated to explore machinability of the soda lime glass. The heat assisted machining thus generates low surface finish on the machined workpiece. The heat assisted high speed end milling of soda lime was carried out using uncoated 2 flute carbide end mill at a constant depth of cut 25 μm, while the spindle speed and feed rate were varied from 30,000 to 50,000 rpm and 45 to 75 mm/min, respectively. The applied temperature was varied from 200 °C to 300 °C. The observations of machined surface were done on Surf-test (SV-514) and Scanning Electron microscope (SEM). A quadratic model for roughness (Ra) was developed using Central Composite Design of experiment. The optimum Ra, 0.10 μm was achieved at 49,570 rpm, 58 mm/min feed rate and heating temperature at 238°C. It is found that cutting speed has the greatest influence on the surface roughness value, followed by feed rate and heating temperature.

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Fuzzy Control of Spindle Torque in High-Speed Milling Processes

Journal of Manufacturing Science and Engineering ◽

10.1115/1.2194063 ◽

2006 ◽

Vol 128 (4) ◽

pp. 1014-1018 ◽

Cited By ~ 16

Author(s):

Rodolfo Haber-Guerra ◽

Steven Y. Liang ◽

José R. Alique ◽

Rodolfo Haber-Haber

Keyword(s):

Control System ◽

Feed Rate ◽

High Speed ◽

Fuzzy Controller ◽

Removal Rate ◽

Spindle Speed ◽

Torque Control ◽

Numerical Control ◽

Open Architecture ◽

High Speed Milling

This paper presents the design and implementation of a two-input/two-output fuzzy logic-based torque control system embedded in an open architecture computer numerical control (CNC) for optimizing the material removal rate in high-speed milling processes. The control system adjusts the feed rate and spindle speed simultaneously as needed to regulate the cutting torque using the CNC’s own resources. The control system consists of a two-input (i.e., torque error and change of error), two-output (i.e., feed rate and spindle speed increment) fuzzy controller, which is embedded within the kernel of a standard open control. Two approaches are tested, and their performance is assessed using several performance measurements. These approaches are a two-input/two-output fuzzy controller and a single-output (i.e., feed rate modification only) fuzzy controller. The results demonstrate that the proposed control strategy provides better accuracy and machining cycle time than other strategies, thus increasing the metal removal rate.

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Investigations into high-speed rough and finish end-milling of hardened EN24 steel for implementation of control strategies

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-012-3915-8 ◽

2012 ◽

Vol 63 (1-4) ◽

pp. 391-406 ◽

Cited By ~ 7

Author(s):

S. Saikumar ◽

M. S. Shunmugam

Keyword(s):

High Speed ◽

End Milling ◽

Control Strategies ◽

Hardened En24

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Cutting Temperature Investigation of AISI H13 in High Speed End Milling

International Journal of Engineering Materials and Manufacture ◽

10.26776/ijemm.01.01.2016.06 ◽

2016 ◽

Vol 1 (1) ◽

pp. 27-34

Author(s):

Muhammad Riza ◽

Erry Y. T. Adesta

Keyword(s):

Feed Rate ◽

High Speed ◽

Turning Point ◽

Tool Path ◽

End Milling ◽

Cutting Temperature ◽

Cutting Speed ◽

Milling Operations ◽

Aisi H13 ◽

Coated Carbide

Heat produced at the tool-chip interface during high speed milling operations have been known as a significant factor that affect to tool life and workpiece geometry or properties. This paper aims to investigate cutting temperature behaviours of AISI H13 (48 HRC) under high speed machining circumstances during pocketing. The experiments were conducted on CNC vertical machining centre by using PVD coated carbide insert. Milling processes were done at cutting speeds 150, 200 and 250 m/min and feed rate were 0.05, 0.1 and 0.15 mm/tooth. Depths of cut applied were 0.1, 0.15 and 0.2 mm. Tool path method applied in this experiment was contour in. Results presented in this paper indicate that by increasing cutting speed the cutting temperature is lower than low cutting speed. However, by decreasing feed rate leads to cutting temperature low. Cutting temperature phenomena at the corner of pocket milling were also investigated. The phenomena showed that cutting temperature tends to decrease a moment when cutter comes to the corner of pocket and turning point of tool path and increase extremely a moment before leaving the corner and turning point.

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Control System for Suppressing Tracking Error Offset and Multiharmonic Disturbance in High-Speed Optical Disk Systems

IEEJ Transactions on Industry Applications ◽

10.1541/ieejias.132.347 ◽

2012 ◽

Vol 132 (3) ◽

pp. 347-356 ◽

Cited By ~ 1

Author(s):

Yuta Nabata ◽

Tatsuya Nakazaki ◽

Tokoku Ogata ◽

Kiyoshi Ohishi ◽

Toshimasa Miyazaki ◽

...

Keyword(s):

Control System ◽

High Speed ◽

Tracking Error ◽

Optical Disk

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DESIGN OF FLY-BY-WIRE CONTROL SYSTEM ALGORITHMS FOR ADVANCED HIGH-SPEED HELICOPTER

TsAGI Science Journal ◽

10.1615/tsagiscij.2015014083 ◽

2015 ◽

Vol 46 (3) ◽

pp. 259-287

Author(s):

Viktor Andreevich Anikin ◽

Oleg Vladimirovich Animitsa ◽

Vladimir Mikhailovich Kuvshinov ◽

Veniamin Aleksandrovich Leontiev

Keyword(s):

Control System ◽

High Speed

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Direct Current Deadbeat Predictive Controller for BLDC Motor Using Single DC-Link Current Sensor

Engineering and Technology Journal ◽

10.30684/etj.v38i8a.471 ◽

2020 ◽

Vol 38 (8A) ◽

pp. 1187-1199

Author(s):

Qaed M. Ali ◽

Mohammed M. Ezzalden

Keyword(s):

Control System ◽

High Speed ◽

Fast Response ◽

Bldc Motor ◽

Current Controller ◽

Three Phase ◽

Predictive Controller ◽

Two Phases ◽

Dc Current ◽

Three Phase Inverter

BLDC motors are characterized by electronic commutation, which is performed by using an electric three-phase inverter. The direct control system of the BLDC motor consists of double loops; including the inner-loop for current regulating and outer-loop for speed control. The operation of the current controller requires feedback of motor currents; the conventional current controller uses two current sensors on the ac side of the inverter to measure the currents of two phases, while the third current would be accordingly calculated. These two sensors should have the same characteristics, to achieve balanced current measurements. It should be noted that the sensitivity of these sensors changes with time. In the case of one sensor fails, both of them must be replaced. To overcome this problem, it is preferable to use one sensor instead of two. The proposed control system is based on a deadbeat predictive controller, which is used to regulate the DC current of the BLDC motor. Such a controller can be considered as digital controller mode, which has fast response, high precision and can be easily implemented with microprocessor. The proposed control system has been simulated using Matlab software, and the system is tested at a different operating condition such as low speed and high speed.

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Ultrasonic sensor system for the uses in intelligent motion control system of a mobile robots group

Proceedings of the Mavlyutov Institute of Mechanics ◽

10.21662/uim2010.1.009 ◽

2010 ◽

Vol 7 ◽

pp. 109-117

Author(s):

O.V. Darintsev ◽

A.B. Migranov ◽

B.S. Yudintsev

Keyword(s):

Control System ◽

Mobile Robot ◽

Mobile Robots ◽

Motion Control ◽

High Speed ◽

Ultrasonic Sensor ◽

Sensor System ◽

Motion Control System ◽

Speed Sensor ◽

Working Space

The article deals with the development of a high-speed sensor system for a mobile robot, used in conjunction with an intelligent method of planning trajectories in conditions of high dynamism of the working space.

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