Stability-based spindle speed control during flexible workpiece high-speed milling

2008 ◽  
Vol 48 (2) ◽  
pp. 184-194 ◽  
Author(s):  
I. Mañé ◽  
V. Gagnol ◽  
B.C. Bouzgarrou ◽  
P. Ray
Keyword(s):  
High Speed ◽  
Speed Control ◽  
Spindle Speed ◽  
High Speed Milling ◽  
Flexible Workpiece

scholarly journals Effect of High Speed Milling Process Parameters on the Milling Force and Surface Topography of AM50A Magnesium Alloy

2018 ◽  
Vol 36 (1) ◽  
pp. 124-131
Author(s):  
Hongji Zhang ◽  
Yuanyuan Ge ◽  
Hong Tang ◽  
Yaoyao Shi ◽  
Zengsheng Li
Keyword(s):  
Magnesium Alloy ◽  
Surface Quality ◽  
High Speed ◽  
Milling Process ◽  
Spindle Speed ◽  
Feed Speed ◽  
Milling Force ◽  
High Speed Milling ◽  
Milling Parameters

Within the scope of high speed milling process parameters, analyzed and discussed the effects of spindle speed, feed rate, milling depth and milling width on milling forces in the process of high speed milling of AM50A magnesium alloy. At the same time, the influence of milling parameters on the surface roughness of AM50A magnesium alloy has been revealed by means of the measurement of surface roughness and surface micro topography. High speed milling experiments of AM50A magnesium alloy were carried out by factorial design. Form the analysis of experimental results, The milling parameters, which have significant influence on milling force in high speed milling of AM50A magnesium alloy, are milling depth, milling width and feed speed, and the nonlinear characteristics of milling force and milling parameters. The milling force decreases with the increase of spindle in the given mill parameters. For the effects of milling parameters on surface quality of the performance, in the milling depth and feeding speed under certain conditions with the spindle speed increases the surface quality of AM50A magnesium alloy becomes better with the feed speed increases the surface quality becomes poor. When the spindle speed is greater than 12000r/min, the milling depth is less than 0.2mm, and the feed speed is less than 400mm/min, the milling surface quality can be obtained easily.

scholarly journals SUPPRESSION OF PERIOD DOUBLING CHATTER IN HIGH-SPEED MILLING BY SPINDLE SPEED VARIATION

2011 ◽  
Vol 15 (2) ◽  
pp. 153-171 ◽  
Author(s):  
Sébastien Seguy ◽  
Tamás Insperger ◽  
Lionel Arnaud ◽  
Gilles Dessein ◽  
Grégoire Peigné
Keyword(s):  
High Speed ◽  
Period Doubling ◽  
Spindle Speed ◽  
High Speed Milling ◽  
Speed Variation ◽  
Spindle Speed Variation

Avoiding Instability on the Milling of Parts with Thin Features

2006 ◽  
Vol 526 ◽  
pp. 37-42 ◽  
Author(s):  
Francisco Javier Campa ◽  
Luis Norberto López de Lacalle ◽  
S. Herranz ◽  
Aitzol Lamikiz ◽  
A. Rivero
Keyword(s):  
Dynamic Model ◽  
High Speed ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Test Device ◽  
High Speed Milling ◽  
Thin Walls ◽  
Chatter Vibrations ◽  
The Stability ◽  
Selection Of

In this paper, a 3D dynamic model for the prediction of the stability lobes of high speed milling is presented, considering the combined flexibility of both tool and workpiece. The main aim is to avoid chatter vibrations on the finish milling of aeronautical parts, which include thin walls and thin floors. In this way the use of complex fixtures is eliminated. Hence, an accurate selection of both axial depth of cut and spindle speed can be accomplished. The model has been validated by means of a test device that simulates the behaviour of a thin floor.

Simultaneous Optimization of Removal Rate and Part Accuracy in High-Speed Milling

2004 ◽  
Author(s):  
Mohammad H. Kurdi ◽  
Tony L. Schmitz ◽  
Raphael T. Haftka ◽  
Brian P. Mann
Keyword(s):  
Optimization Algorithm ◽  
High Speed ◽  
Removal Rate ◽  
Spindle Speed ◽  
Successful Implementation ◽  
Location Error ◽  
High Speed Milling ◽  
Surface Location Error ◽  
Surface Location ◽  
Selection Of

High-speed milling provides an efficient method for accurate discrete part fabrication. However, successful implementation requires the selection of appropriate operating parameters. Balancing the multiple process requirements, including high material removal rate, maximum part accuracy, sufficient tool life, chatter avoidance, and adequate surface finish, to arrive at an optimum solution is difficult without the aid of an optimization framework. In this paper an initial effort is made to apply analytical tools to the selection of optimum cutting parameters (spindle speed and depth of cut are considered at this stage). Two objectives are addressed simultaneously, maximum removal rate and minimum surface location error. The Time Finite Element Analysis method is used in the optimization algorithm. Sensitivity of the surface location error to small changes in spindle speed near tooth passing frequencies that are integer fractions of the system’s natural frequency corresponding to the most flexible mode is calculated. Results of the optimization algorithm are verified by experiment.

scholarly journals Influence of the Cut Axial Depth on Surface Roughness at High-Speed Milling of Thin-Walled Workpieces

2021 ◽  
Vol 20 (2) ◽  
pp. 127-131
Author(s):  
A. I. Germashev ◽  
V. A. Logominov ◽  
S. I. Dyadya ◽  
Y. V. Kozlova ◽  
V. A. Krishtal
Keyword(s):  
High Speed ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Natural Vibration Frequency ◽  
High Speed Milling ◽  
Wide Range ◽  
Thin Walled ◽  
Axial Depth

The paper presents the results of research on the dynamics of end milling of thin-walled work-pieces having complex geometric shapes. Since the milling process with shallow depths of cut is characterized by high intermittent cutting, the proportion of regenerative vibrations decreases, and the effect of forced vibrations on the dynamics of the process, on the contrary, increases. The influence of  axial depth of cut on the vibrations arising during processing, and roughness of the processed surface have been studied in paper.  The experiments have been carried out in a wide range of changes in the spindle speed at different axial cutting depths.  Vibrations of a thin-walled work-piece  have been recorded with an inductive sensor and recorded in digital form. Then an oscillogram has been used to estimate the amplitude and frequency of oscillations. The profilograms of the machined surface have been analysed. Roughness has been evaluated by the parameter Ra. The results have shown similar relationships for each of the investigated axial cutting depths. The worst cutting conditions  have been observed when the natural vibration frequency coincided with the tooth frequency or its harmonics. It is shown that the main cause of vibrations in high-speed milling  is forced rather than regenerative vibrations. Increasing the axial depth of cut at the same spindle speed increases the vibration amplitude. However, this does not significantly affect the roughness of the processed surface in cases when it comes to vibration-resistant processing.

Experimental Study on High-Speed Milling of Aluminum Alloy 2A70

2011 ◽  
Vol 314-316 ◽  
pp. 1788-1791 ◽  
Author(s):  
Feng Yun Yu ◽  
Ming Jun Feng ◽  
Ming Jun Dai ◽  
Hong Jiang Sun
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
High Speed ◽  
Periodic Variation ◽  
Spindle Speed ◽  
Milling Force ◽  
Experimental Conditions ◽  
High Speed Milling ◽  
High Speed Cutting ◽  
Test Study

High-speed cutting technology is widely used in aviation, mold, automotive industries and other fields for its high machining efficiency, smaller cutting force, less cutting heat and high machining precision. However, the production site in China, high-speed machine tools do not really play its role in some enterprises, without real sense of the high-speed machining. Aluminum alloy 2A70 as the research object, using single-factor test, study the effect law of high-speed milling parameters on milling force here. The results show that: the cutting force is varying for high-speed milling, showing a periodic variation, with the transient characteristic, the milling force is large amplitude fluctuations in X and Y direction, the amount of change is respectively 55.544N and 56.306N. Milling force influenced by the spindle speed, with the increase of spindle speed, X contribute to the greatest change in the direction of milling, Y direction second, Z direction is almost unchanged. Under the experimental conditions, the stability high-speed cutting area of 2A70 is the spindle speed in the area of 21000rpm~27000rpm. The results of high-speed milling of aluminum alloy have certain significance.

Influence of spindle speed on tool wear in high-speed milling of Inconel 718 curved surface parts

2016 ◽  
Vol 232 (8) ◽  
pp. 1331-1341 ◽  
Author(s):  
Jianwei Ma ◽  
Yuanyuan Gao ◽  
Zhenyuan Jia ◽  
Dening Song ◽  
Likun Si
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Inconel 718 ◽  
High Speed ◽  
Spindle Speed ◽  
Curved Surface ◽  
Machining Efficiency ◽  
High Speed Milling ◽  
Coated Tool ◽  
Curved Surface Parts

High-speed milling, which provides an efficient approach for high-quality machining, is widely adopted for machining difficult-to-machine materials such as Inconel 718. For high-speed milling of Inconel 718 curved surface parts, the spindle speed which determines cutting speed directly is regarded as an important cutting parameter related to tool wear and machining efficiency. Meanwhile, because of the changing geometric features of curved surface, cutting force is changing all the time with the variation of geometric features, which influences not only tool wear but also machining quality significantly. In this study, the influence of spindle speed on coated tool wear in high-speed milling of Inconel 718 curved surface parts is studied through a series of experiments on considering tool life, cutting force, cutting force fluctuation, and machining efficiency. According to the experimental results, the appropriate spindle speed that can balance both the tool life and the machining efficiency is selected as 10,000 r/min for high-speed milling of Inconel 718 curved surface parts. In addition, the coated tool wear mechanism is investigated through scanning electron microscopy–energy dispersive x-ray spectroscopy analysis. The results show that at the beginning wear stage and the stable wear stage, the coated tool wear is mainly caused by mechanical wear. Then, with the increasing cutting temperature due to the blunt tool edge, the tool wear becomes compound wear which contains more than one wear form so as to cause a severe tool wear.

Experimental Research on Surface Roughness in High Speed Milling of Complex Surface Mold Steel

2009 ◽  
Vol 626-627 ◽  
pp. 123-128 ◽  
Author(s):  
Cao Qing Yan ◽  
Jun Zhao ◽  
Yue En Li ◽  
Shi Guo Han
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Tool Path ◽  
High Efficiency ◽  
Complex Surface ◽  
Spindle Speed ◽  
Cnc Milling ◽  
Cutting Depth ◽  
High Speed Milling ◽  
Longitudinal Roughness

Complex surface mold has been widely used in various industries, and high efficiency and high quality can been achieved through high-speed CNC milling processing. Surface roughness including transverse and longitudinal roughness is an important criterion for mold quality. A high-speed milling experiment was performed in mold steel P20 using cemented carbide ball-end mill to investigate the surface roughness. The effects of process parameters on roughness including spindle speed, feed per tooth and radial cutting depth were examined, and an analysis on the mechanism for two kinds of roughness of different tool paths was finished. The experimental results show that the longitudinal roughness improve obviously while the spindle speed and the feed per tooth increase on the high-speed conditions, and the transverse roughness increase significantly when the radial cutting depth increases. And for a smaller roughness value, the tool path should be selected along the direction in which the curvature changes evidently.

Chatter Stability Prediction in High Speed Milling Considering Multi-Degree of Freedom

2010 ◽  
Vol 431-432 ◽  
pp. 373-376
Author(s):  
Shan Shan Sun ◽  
Wei Xiao Tang ◽  
Xi Qing Xu
Keyword(s):  
High Speed ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Stability Prediction ◽  
High Speed Milling ◽  
Stability Lobes ◽  
Milling Operations ◽  
Critical Requirement ◽  
Multi Mode

Chatter problems occurring during high speed milling affect the quality of the finished workpiece and, to a lesser extent, the tool life and the spindle life. Therefore, the prediction of stable milling regions is a critical requirement for high speed milling operations. In this paper, a dynamic model of a high speed spindle system considering the multi-mode dynamics is elaborated for the purposed of stability prediction. A stability lobes diagram (SLD) shows the boundary between chatter-free machining operations and unstable processes, in terms of axial depth of cut as a function of spindle speed. These diagrams are used to select chatter-free combinations of machining parameters. The proposed method enables a new stability lobes diagram to be established that takes into account the effect of spindle speed on multi-mode dynamic behavior.

scholarly journals Analysis of Cutting Forces From Conventional to High-Speed Milling with Straight and Helical-Flute Tools for Flat-End Milling Incorporating the Effect of Tool Runout

2021 ◽  
Author(s):  
Mehmet AYDIN ◽  
Uğur Köklü
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Spindle Speed ◽  
Force Model ◽  
Workpiece Material ◽  
High Speed Milling ◽  
Tool Runout ◽  
Flat End Milling

Abstract This paper presents a systematic study to analyze the dependence of cutting forces on tool geometry, workpiece material and cutting parameters such as spindle speed, tool engagement and cutting direction in flat-end milling with tool runout. The cutting forces are determined according to a mechanistic force model considering the trochoidal flute path to calculate the undeformed chip thickness, and average cutting force and linear regression model are applied for identifying the coefficients of the force model. A series of milling processes are conducted on AZ31 Magnesium (Mg) alloy and titanium alloy (Ti6Al4V) to analyze the instantaneous cutting force curves, amplitudes of cutting forces and peak forces over a wide range of spindle speeds from conventional to high-speed milling. It is demonstrated that the values of the cutting force coefficients are higher at conventional spindle speed and decrease with an increase in spindle speed, especially when machining Ti6Al4V alloy. For the edge force coefficients, it is observed a slight variation when using cutting tools with different helix angles. Besides, the cutting force amplitudes strongly depend upon the workpiece material. The helix angle has a significant influence on the transverse force amplitude at conventional speed. The forces obtained mechanistically are also substantiated by comparison with measurements.

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