scholarly journals A technique of experiment aided virtual prototyping to obtain the best spindle speed during face milling of large-size structures

Meccanica ◽  
2020 ◽  
Author(s):  
Krzysztof J. Kalinski ◽  
Marek A. Galewski ◽  
Michal R. Mazur ◽  
Natalia Morawska
Keyword(s):  
Virtual Prototyping ◽  
Face Milling ◽  
Spindle Speed ◽  
Large Size

scholarly journals An Experimentally Aided Operational Virtual Prototyping to Obtain the Best Spindle Speed during Face Milling of Large-Size Structures

Materials ◽  
2021 ◽  
Vol 14 (21) ◽  
pp. 6562
Author(s):  
Krzysztof J. Kaliński ◽  
Marek A. Galewski ◽  
Michał R. Mazur ◽  
Natalia Stawicka-Morawska
Keyword(s):  
Original Method ◽  
Milling Process ◽  
Face Milling ◽  
Spindle Speed ◽  
Experimental Investigations ◽  
Process Data ◽  
Large Size ◽  
Operational Technique ◽  
Production Practice ◽  
Modal Model

The paper presents an original method concerning the problem of vibration reduction in the general case while milling large-size and geometrically complex details with the use of an innovative approach to the selection of spindle speed. A computational model is obtained by applying the so-called operational approach to identify the parameters of the workpiece modal model. Thanks to the experimental modal analysis results, modal subsystem identification was performed and reliable process data for simulation studies were obtained. Next, simulations of the milling process, for successive values of the spindle speed, are repeated until the best vibration state of the workpiece is obtained. For this purpose, the root mean square values of the time plots of vibration displacements are examined. The effectiveness of the approach proposed for reducing vibrations in the process of face milling is verified on the basis of the results of appropriate experimental investigations. The economic profitability of the implementation of the operational technique in the production practice of enterprises dealing with mechanical processing is demonstrated as well.

scholarly journals A method of predicting the best conditions for large-size workpiece clamping to reduce vibration in the face milling process

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Krzysztof J. Kaliński ◽  
Natalia Stawicka-Morawska ◽  
Marek A. Galewski ◽  
Michał R. Mazur
Keyword(s):  
Natural Frequencies ◽  
Vibration Suppression ◽  
Milling Process ◽  
Face Milling ◽  
Modal Identification ◽  
Large Size ◽  
Innovative Method ◽  
The Face ◽  
The Time Domain ◽  
Minimum Work

AbstractThe paper presents an innovative method of solving the problem of vibration suppression during milling of large-size details. It consists in searching for the best conditions for clamping the workpiece based on a rapid modal identification of the dominant natural frequencies only and requires repetitive changes in the tightening torque of the clamping screws. Then, by estimating the minimum work of the cutting forces acting in the direction of the width of the cutting layer, it is possible to predict the best fixing of the workpiece. Application of the method does not require the creation and identification of a computational model of the process or preliminary numerical simulations. The effectiveness of this method was confirmed by the evaluation of the Root Mean Square (RMS) of the vibration level in the time domain observed during the actual face milling process. The worst results were obtained for the configuration of supports tightened with a torque of 90–110 Nm, and the best—with a torque of 50 Nm.

Wear of Throwing End of Vertical Shaft Impact Crusher

2012 ◽  
Vol 155-156 ◽  
pp. 501-504
Author(s):  
Jun Ming Zhang
Keyword(s):  
Dynamic Simulation ◽  
Working Conditions ◽  
Virtual Prototyping ◽  
Critical Issue ◽  
Rotor System ◽  
Spindle Speed ◽  
Vertical Shaft ◽  
Cast Material ◽  
System A ◽  
Main Material

Statistics show that China currently applied in the vertical shaft impact crusher, the intensity itself is not a major problem affecting the life, the most critical issue is the main material throw head wear . Vertical shaft impact crusher rotor system based on virtual prototyping, combined with the actual working conditions and research objectives, in ADAMS dynamic simulation of the rotor system, a spindle speed at 1600r/min obtained when different materials on the first intermediate principal cast material suffered impact relationships

scholarly journals Study Regarding the Optimal Milling Parameters for Finishing 3D Printed Parts from ABS and PLA Materials

2018 ◽  
Vol 70 (1) ◽  
pp. 66-72 ◽  
Author(s):  
Răzvan Gabriel Pămărac ◽  
Radu Emanuil Petruse
Keyword(s):  
Face Milling ◽  
Spindle Speed ◽  
Milling Parameters ◽  
3D Printed ◽  
Finishing Processes

Abstract In this paper we proposed to identify the optimum milling parameter required for finishing processes performed on 3Dprinted parts from ABS and PLA materials. We have identified the optimum milling parameters for a constant spindle speed of 3500 rot/min for face milling and profile contouring operations with different tools diameters. The study was performed on 3D printed specimens from ABS and PLA materials.

Evaluation of Face Milling Operation Parameters on Surface Roughness of Crankcase Housing by Two Level Factorial Design with Center Points

2018 ◽  
Vol 780 ◽  
pp. 105-110
Author(s):  
Ukrit Thanasuptawee ◽  
Chamrat Thakhamwang ◽  
Somsak Siwadamrongpong
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Milling Process ◽  
Face Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Significance Level ◽  
Machining Center ◽  
Semi Solid

In this study, there are three machining parameters consist of spindle speed, feed rate and depth of cut which were conducted through full factorial with four center points to determine the effect of machining parameters on the surface roughness and verify whether there is curvature in the model for CNC face milling process in an automotive components manufacturer in Thailand. The workpieces used semi-solid die casted ADC12 aluminum alloy crankcase housing which they were performed by the ARES SEIKI model R5630 3-axis CNC vertical machining center and face milling cutter with diameter of 63 millimeters. The surface roughness of face-milled was measured by the surface roughness tester. It was found that the greatest main effect influence to surface roughness was spindle speed, followed by feed rate and depth of cut at significance level of 0.05.

scholarly journals A Method of Predicting The Best Conditions for Clamping a Large-Size Workpiece in Order To Reduce Vibrations in The Milling Process

2021 ◽  
Author(s):  
Krzysztof J. Kaliński ◽  
Natalia Stawicka-Morawska ◽  
Marek A. Galewski ◽  
Michał R. Mazur
Keyword(s):  
Natural Frequencies ◽  
Vibration Suppression ◽  
Milling Process ◽  
Face Milling ◽  
Modal Identification ◽  
Vibration Level ◽  
Large Size ◽  
Innovative Method ◽  
The Time Domain ◽  
Minimum Work

Abstract The paper presents an innovative method of solving the problem of vibration suppression during milling of large-size details. It consists in searching for the best conditions for clamping the workpiece based on a rapid modal identification of the dominant natural frequencies only and requires repetitive changes in the tightening torque of the clamping screws. Then, by estimating the minimum work of the cutting forces acting in the direction of the width of the cutting layer, it is possible to predict the best fixing of the workpiece. Application of the method does not require the creation and identification of a computational model of the process or preliminary numerical simulations. The effectiveness of this method was confirmed by the evaluation of the Root Mean Square (RMS) of the vibration level in the time domain observed during the actual face milling process.

Floquet Theory Based Approach for Stability Analysis of the Variable Speed Face-Milling Process

2001 ◽  
Vol 124 (1) ◽  
pp. 10-17 ◽  
Author(s):  
Sridhar Sastry ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor
Keyword(s):  
Stability Analysis ◽  
Floquet Theory ◽  
Milling Process ◽  
Face Milling ◽  
Spindle Speed ◽  
Spindle Speed Variation ◽  
Modes Of Vibration ◽  
Varying Time Delay ◽  
Constant Coefficients ◽  
System Equations

This paper presents a new method for stability analysis of the variable spindle speed face milling process whose dynamics are described by a set of differential-difference equations with periodic coefficients and time varying time delay. Fourier analysis and Floquet theory applied to the system equations result in a characteristic equation of infinite order with constant coefficients. Its truncated version is used to determine the limit of stability by employing standard techniques of control theory. Analytically predicted stability boundaries are compared with lobes generated by time domain simulations. Experimental results are also presented that validate the proposed analytical method for chatter stability analysis. Finally, an example is presented that demonstrates the advantage of using spindle speed variation when machining a workpiece having multiple modes of vibration.

The Trial Research on Suppressing the Chatter by Variable Speed Milling

2011 ◽  
Vol 291-294 ◽  
pp. 2010-2013 ◽  
Author(s):  
Zhi Jian Gou
Keyword(s):  
Cutting Tool ◽  
Face Milling ◽  
Spindle Speed ◽  
Cutting Process ◽  
Variable Speed ◽  
Trajectory Parameter ◽  
Speed Variation ◽  
Cutting Chatter ◽  
Speed Parameter ◽  
Tool Cutting

The vibration occurring in cutting process is a very harmful phenomenon, which destroys the surface finish and dimensional integrity of workpieces and quickens the wear of cutting tool. Cutting chatter can be suppressed or reduced by applying the method of suppressing chatter by variable speed cutting. In order to investigate the effect of variable speed parameters and cutting conditions on suppressing the chatter in face milling, the tests have been conducted.The results have shown that cutting with variable spindle speed cutting in face milling will suppress the development of chatter. If chatter occurs in cutting process, the vibration amplitude of variable speed cutting can reduce by 3-6 times lower than that of constant speed cutting, as long as the variable speed parameter are selected suitably.The values of speed variation amplitude Δn/no and speed variation frequency fn of spindle speed trajectory parameter have great effect on suppressing chatter, Δn/no = 15- 20% and fn = 0.4 - 0.5Hz are suitable.

scholarly journals Optimizing Cutting Conditions for Minimum Surface Roughness in Face Milling of High Strength Steel Using Carbide Inserts

2016 ◽  
Vol 2016 ◽  
pp. 1-14 ◽  
Author(s):  
Adel Taha Abbas ◽  
Adham Ezzat Ragab ◽  
Essam Ali Al Bahkali ◽  
Ehab Adel El Danaf
Keyword(s):  
Surface Roughness ◽  
Factorial Design ◽  
Feed Rate ◽  
High Strength Steel ◽  
High Strength ◽  
Face Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Quadratic Term ◽  
Machining Parameters

A full factorial design technique is used to investigate the effect of machining parameters, namely, spindle speed(N), depth of cut(ap),and table feed rate(Vf),on the obtained surface roughness (RaandRt) during face milling operation of high strength steel. A second-order regression model was built using least squares method depending on the factorial design results to approximate a mathematical relationship between the surface roughness and the studied process parameters. Analysis of variance was conducted to estimate the significance of each factor and interaction with respect to the surface roughness. ForRa, the results show that spindle speed, depth of cut, and table feed rate have a significant effect on the surface roughness in both linear and quadratic terms. There is also an interaction between depth of cut and feed rate. It also appears that feed rate has the greatest effect on the data variation followed by depth of cut. ForRt, the results show that the table feed rate is the most effective factor followed by the depth of cut, while the spindle speed had a significant small effect only in its quadratic term. The conditions of minimumRaandRtare identified through least square optimization. Moreover, multiobjective optimization for minimizingRaand maximizing metal removal rateQis conducted and the results are presented.

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