An analytical prediction model of surface topography generated in 4-axis milling process

2021 ◽  
Author(s):  
Ruihu Zhou ◽  
Qinlin Chen
Keyword(s):  
Prediction Model ◽  
Surface Topography ◽  
Milling Process ◽  
Analytical Prediction

Analytical Prediction and Experimental Investigation of Burnishing Force in Rotary Ultrasonic Roller Burnishing Titanium Alloy Ti–6Al–4V

2020 ◽  
Vol 142 (3) ◽  
Author(s):  
Jian Zhao ◽  
Zhanqiang Liu ◽  
Bing Wang ◽  
Yukui Cai ◽  
Qinghua Song
Keyword(s):  
Titanium Alloy ◽  
Prediction Model ◽  
Milling Process ◽  
Analytical Prediction ◽  
Ultrasonic Power ◽  
Machined Surface ◽  
Softening Effect ◽  
Force Prediction ◽  
Contact Width ◽  
Acoustic Softening

Abstract Ultrasonic burnishing is usually applied to make machined surface modification. The acoustic softening effect caused by ultrasonic vibration is beneficial to the machining of difficult-to-cut materials. In the present work, a burnishing force prediction model was proposed for rotary ultrasonic burnishing of titanium alloy Ti–6Al–4V, whose surface had been machined with the face milling process. Firstly, the contact between the burnishing roller and one single milling mark was analyzed with plane strain assumption based on the Boussinesq–Flamant contact problem. Then, the effect of ultrasonic softening on the yield stress of Ti–6Al–4V was investigated. The critical contact width and contact load that the burnishing roller crushed on one single milling mark were examined to confirm the feasibility of the proposed ultrasonic burnishing force prediction model. The experimental verifications were carried out at various ultrasonic powers. The burnishing forces from experiment measurements were consistent with the calculated results from the proposed model. The mean deviations between theoretical and experimental results of the ultrasonic burnishing force were 10.4%, 12.2%, and 15.2%, corresponding to the ultrasonic power at the level of 41 W, 158 W, and 354 W, respectively.

Vibration Analysis of High-Speed End Milling Operations Applied to Injection Mold Materials

2017 ◽  
Author(s):  
Andris Logins ◽  
Toms Torims ◽  
Pedro Rosado Castellano ◽  
Santiago Gutiérrez ◽  
Rafael Torres
Keyword(s):  
Prediction Model ◽  
Surface Topography ◽  
High Speed ◽  
End Milling ◽  
Dynamical Behavior ◽  
Milling Process ◽  
Injection Mold ◽  
High Speed Milling ◽  
3D Surface Topography ◽  
End Milling Process

High-speed milling has often been applied in injection mold manufacturing processes, where surface roughness is a significant criterion in product quality demands. It is equally applicable to automotive or industrial engineering and to toy manufacturing, where plastic parts with a high-quality surface finish have been processed using the injection molding technique. High-speed milling involves a number of process parameters that may affect the 3D surface topography formation. Literature analysis reveals that dynamical behavior is a significant factor in the end milling process on surface roughness parameters. To improve the accuracy of predicted surface topography models, it is important to include the dynamical behavior of milling factor. This paper describes the surface prediction model of combined end-milling geometrical and dynamical interaction models. The natural frequency of machine assembly and forced vibrations during the cutting process were measured during the flat-end milling process. Unevenly distributed cutting marks were revealed by surface 3D topography images and microscopy images of the machined samples. A mathematical model to predict surface topography was developed, including dynamical behavior and cutting geometries. Machine accuracy also has to be addressed. 3D surface topography parameters from the experimental sample provided the results for the mathematical prediction model. This model offers a software tool for manufacturers to improve the quality of machined part surfaces, taking into account the behavioral properties of their machining equipment. Relevant conclusions about the manufacturing equipment accuracy have been drawn. Vibrations in the milling system affect the cutting process and contribute to the surface topography prediction model. Local cutting tool vibrations do not have any influence on surface parameter mean values.

Milling Force Prediction for Circular Contour Machining

2014 ◽  
Vol 800-801 ◽  
pp. 243-248
Author(s):  
Kai Zhao ◽  
Zhan Qiang Liu
Keyword(s):  
Prediction Model ◽  
Milling Process ◽  
Machining Process ◽  
Curvature Radius ◽  
Force Model ◽  
Milling Force ◽  
Circular Contour ◽  
The Mean ◽  
Contour Machining ◽  
Matlab Programming

When machining the complex parts of aircraft engines, the milling force for the circular contour must be accurately predicted to reduce machining vibration. In this paper, the prediction model of the mean milling force per tooth during machining circular contour is developed. Firstly, the formulas of the entry angle, the exit angle and the equivalent feed per tooth are established through the analysis of circular contour milling process. Then, the equation of the mean milling force per tooth is deduced based on mechanistic force model during the circular contour machining process. Finally, the prediction model of mean milling force per tooth during machining circular contour is developed using MATLAB programming. The relationship between the milling force per tooth and surface curvature radius of the machined workpiece is also analyzed in this paper.

scholarly journals An Analytical Prediction Model of Time Diversity Performance for Earth-Space Fade Mitigation

2008 ◽  
Vol 2008 ◽  
pp. 1-5 ◽  
Author(s):  
Pantelis-Daniel M. Arapoglou ◽  
Athanasios D. Panagopoulos ◽  
Panayotis G. Cottis
Keyword(s):  
Prediction Model ◽  
High Frequency ◽  
Rain Attenuation ◽  
Analytical Prediction ◽  
Time Dynamics ◽  
Time Diversity ◽  
Satellite Applications ◽  
Basic Parameters ◽  
Cost Efficient ◽  
General Prediction

Time diversity (TD) has recently attracted attention as a promising and cost-efficient solution for high-frequency broadcast satellite applications. The present work proposes a general prediction model for the application of TD by approximating the time dynamics of rain attenuation through the use of the joint lognormal distribution. The proposed method is tested against experimental data and its performance is investigated with respect to the basic parameters of a satellite link.

scholarly journals Prediction Modeling and Sensitivity Analysis of Robot Bone Milling Temperature Operated by a Doctor

2021 ◽  
Vol 2021 ◽  
pp. 1-17
Author(s):  
Heqiang Tian ◽  
Jingbo Pan ◽  
Yu Gao ◽  
Xiaoqing Dang ◽  
Bin Tian ◽  
...  
Keyword(s):  
Prediction Model ◽  
Cortical Bone ◽  
Cancellous Bone ◽  
Bone Cells ◽  
Prediction Method ◽  
Milling Process ◽  
Milling Parameters ◽  
Cutting Surface ◽  
Milling Temperature ◽  
Cutting Modes

Bone milling is a common method in robot orthopedic surgery. However, excessive milling temperature will cause thermal necrosis of bone cells and tissues. It is necessary to carry out further research and analysis on the robot bone milling process considering the lamina milling skills of spinal surgeons and clinical practice to reduce the damage to bone cells and nearby tissues and obtain good cutting surface quality. Considering the randomness of milling parameters during operation, a prediction method of milling temperature model for ball milling cutter considering the doctor’s surgical skills was proposed based on response surface method. Because of material anisotropy and microstructure difference between the cortical bone and cancellous bone, this paper would analyze the influencing factors in different bone layers to establish the prediction model of milling temperature in the segments of cortical bone and cancellous bone. Also, the influence and distribution of milling parameters on temperature in three cutting modes such as parallel cutting mode, cross cutting mode, and vertical cutting mode in the cortical bone region were analyzed. The parameter sensitivity of the milling temperature prediction model was analyzed by the Sobol method, and the influence of the input parameters on the output milling temperature was analyzed quantitatively.

scholarly journals A prediction model of the surface topography due to the unbalance of the spindle system in ultra-precision fly-cutting machining

2018 ◽  
Vol 10 (1) ◽  
pp. 168781401774714
Author(s):  
Dongju Chen ◽  
Xianxian Cui ◽  
Ri Pan ◽  
Jinwei Fan ◽  
Chenhui An
Keyword(s):  
Prediction Model ◽  
Surface Topography ◽  
Rotation Speed ◽  
Surface Generation ◽  
Machining Accuracy ◽  
Machined Surface ◽  
Spindle System ◽  
Fly Cutting ◽  
Ultra Precision ◽  
Aerostatic Spindle

In ultra-precision fly-cutting machining, the aerostatic spindle is the key component, which has significant influence on the machined surface quality. The unbalanced spindle directly affects the machining accuracy. In this article, a prediction model of machining surface topography is proposed which involves the effect of the gas film performance of spindle in microscale. With the Weierstrass function, unstable transient response of the aerostatic spindle system is derived by the motion model of the spindle, which response signal represents the surface profile in the ultra-precision machining. Meanwhile, the experiment is performed with different rotation speed of the spindle. And the effect of the unbalanced aerostatic spindle on the surface generation is discussed in time and frequency domain. The conclusion shows that the similar cyclical surface ripple of the workpiece is independent of the spindle speed, and the rotation speed of the spindle and unbalanced spindle directly affects the machining surface topography. This study is quite meaningful for deeply understanding the influence rule of spindle unbalanced error from the viewpoint of machined surface and vibration frequency.

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