scholarly journals Development of smart machining system for optimizing feedrates to minimize machining time

2017 ◽  
Vol 5 (3) ◽  
pp. 299-304 ◽  
Author(s):  
Hong-seok Park ◽  
Bowen Qi ◽  
Duck-Viet Dang ◽  
Dae Yu Park
Keyword(s):  
Cutting Force ◽  
Machining Process ◽  
Cnc Machine ◽  
Machining Time ◽  
Virtual Machining ◽  
Milling Operations ◽  
Nc Program ◽  
Machining System ◽  
Optimal Feed ◽  
Smart Machining

Abstract Feedrate optimization is an important aspect of getting shorter machining time and increase the potential of efficient machining. This paper presents an autonomous machining system and optimization strategies to predict and improve the performance of milling operations. The machining process was simulated and analyzed in virtual machining framework to extract cutter-workpiece engagement conditions. Cutting force along the cutting segmentation is evaluated based on the laws of mechanics of milling. In simulation, constraint-based optimization scheme was used to maximize the cutting force by calculating acceptable feedrate levels as the optimizing strategy. The intelligent algorithm was integrated into autonomous machining system to modify NC program to accommodate these new feedrates values. The experiment using optimized NC file which generates by our smart machining system were conducted. The result showed autonomous machining system, was effectively reduced 26%. Highlights The smart machining system was implemented in the CNC machine. Optimal feed rates enhance machine tool efficiency. The smart machining system is reliable to reduce machine time.

Tool Posture Planning Method for Low Rigidity Workpiece Considering Elastic Deformation Caused by Cutting Force

2020 ◽  
Author(s):  
Jun'ichi Kaneko ◽  
Yuki Okuma ◽  
Shumpei Sugita ◽  
Takeyuki Abe
Keyword(s):  
Cutting Force ◽  
Elastic Deformation ◽  
Feed Rate ◽  
Machining Process ◽  
Machining Time ◽  
Machined Surface ◽  
Nc Program ◽  
Blade Shape ◽  
Tool Posture ◽  
The Moment

Abstract In machining process for a workpiece with low rigidity such as a blade shape, it is required to consider elastic deformation of the workpiece shape itself due to cutting force. Conventionally, reduction of the cutting force in machining process is achieved by optimization of feed rate value in NC program. On the other hand, since a decrease in the feed rate causes an increase in machining time. So, other optimization algorithm is required. In this paper, a new method to suppress the elastic deformation of the workpiece by changing tool posture in multi-axis controlled machining is proposed. The proposed method is intended for finish machining process for blade shape with a ball end mill. In the proposed method, first, the cutting force loaded on the workpiece surface in a certain posture candidate is predicted, and an instantaneous cutting force at the moment when the machining surface is generated is estimated by model-based computer simulation. Based on this results, the amount of elastic deformation on the machined surface is estimated by FEM. This process is repeated at each cutter location and tool posture candidate, and the new tool posture that can minimize machining error caused by the elastic deformation is determined at each cutter location.

Off-Line Feedrate Optimization Based on Simulation of Cutting Forces

2009 ◽  
Vol 407-408 ◽  
pp. 408-411
Author(s):  
Chen Zhang
Keyword(s):  
Cutting Force ◽  
Optimization Algorithm ◽  
Cutting Forces ◽  
Machining Process ◽  
Machining Time ◽  
Set Constraints ◽  
Machining Quality ◽  
Feedrate Optimization ◽  
Nc Program ◽  
Selection Of

The strategies of selection of feedrate are studied in the ball-end machining process. The optimization algorithm utilizes the objective requirements of a line of NC program to set constraints relation between cutting force and feedrate and optimizes feedrate by controlling the variety ranges of the instantaneous cutting force specified in the cutting forces simulation. Off-line feedrate optimization software for complex sculptured is developed. For a line of NC program, the developed software calculates instantaneous cutting force and an optimization algorithm is used to acquire desired feedrate. The machining experimental results show that the proposed algorithms are satisfying in reduction of machining time and improvement of machining quality.

Contrast Research on Cutting Forces in 4-Axis and 5-Axis Blade Machining Process

2010 ◽  
Vol 142 ◽  
pp. 209-213
Author(s):  
Tong Wu ◽  
Can Zhao ◽  
Guang Bin Bu ◽  
Dun Wen Zuo
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Test Method ◽  
Machining Process ◽  
Paper Test ◽  
Nc Program ◽  
Blade Machining ◽  
The Difference

In this paper, test method was used to study the distribution of cutting force while blade machined with 4-axis and 5-axis NC program. The main difference between the two program was given. The difference of machining forms between 4-axis and 5-axis has led to their cutting forces distribution were different. The change of cutting force in 4-axis machining was large while the 5-axis machining was relatively stable. 5-axis cutting force had no impact comparing with 4-axis, which is more suitable for blade machining.

A Method for Using a Virtual Machining Simulation to Consider Both Equivalent CO2Emissions and Machining Costs in Determining Cutting Conditions

2015 ◽  
Vol 9 (2) ◽  
pp. 115-121 ◽  
Author(s):  
Hirohisa Narita ◽  
Keyword(s):  
Evaluation System ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Machining Process ◽  
Machining Simulation ◽  
End Mill ◽  
Virtual Machining ◽  
Mill Operation ◽  
Nc Program

An evaluation system for calculating equivalent CO2emissions and machining costs is developed using an activity-based model. The system can evaluate a machining process from an NC program, workpiece information, and cutting tool information, and it can then calculate accurate equivalent CO2emissions and the machining cost. The cutting speed of an end mill operation is evaluated in terms of the equivalent CO2emission and the machining cost. Based on the results, optimal cutting conditions are determined to minimize the equivalent CO2emissions and the machining cost to the extent possible.

Development of Cutting Strategy in Ultra-Precision Raster Milling of Freeform Surface

2014 ◽  
Vol 633-634 ◽  
pp. 615-619
Author(s):  
Su Juan Wang ◽  
Su Et To ◽  
Xin Chen ◽  
Jian Qun Liu
Keyword(s):  
Cutting Parameters ◽  
Integrated System ◽  
Machining Process ◽  
Freeform Surface ◽  
Machining Time ◽  
Tool Paths ◽  
Nc Program ◽  
Ultra Precision ◽  
Cutting Strategy

This paper studies the development of cutting strategy in the fabrication of freeform surface in ultra-precision raster milling (UPRM). The tasks of developing cutting strategy in freeform machining involve in the selection of cutting parameters and the planning of tool paths. An integrated system is built in this study to develop the cutting strategy, automatically generate NC program, simulate the tool paths and machining process, as well as make predictions for the machining time and the surface quality of the raster milled freeform surface. Experiment is conducted to verify the developed system and the experimental results show that the system is applicable for the machining of freeform surface in UPRM. This study therefore contributes to avoiding the need to conduct expensive and time consuming trial cutting tests to ensure the product quality in the freeform machining.

scholarly journals Surface Roughness Prediction and Minimization in 5-Axis Milling Operations of Gas Turbine Blades

2021 ◽  
Author(s):  
Arameh Eyvazian ◽  
Farayi Musharavati ◽  
Afrasyab Khan ◽  
Mohsen Soori ◽  
Tamer A. Sebaey ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Gas Turbine ◽  
Turbine Blades ◽  
Machining Process ◽  
Machining Parameters ◽  
Gas Turbine Blades ◽  
Virtual Machining ◽  
Machined Parts ◽  
Machining System

Abstract To enhance the quality of machined parts, virtual machining systems are presented in this study. In the turbine blades, the minimization of the surface roughness of the blades can decrease the Reynolds number to decrease the loss of energy in power generation. Due to difficulties of polishing process in minimizing the surface roughness of machined blades, the optimized machining parameters for minimizing the surface roughness is an effective solution for the problem. In this study, a virtual machining system is developed to predict and minimize the surface roughness in 5-Axis machining operations of gas turbine blades. To minimize the surface roughness, the machining parameters were optimized by the Genetic algorithm. To validate the developed system, the turbine blades were machined using a 5-Axis CNC machine tool and the machined blades were measured using the CMM machine to obtain the surface roughness of machined parts. So, a 41.29% reduction in the measured surface roughness and a 42.09% reduction in the predicted surface roughness are obtained using the optimized machining parameters. The developed virtual machining system can be applied in the machining process of turbine blades to enhance the surface quality of machined blades and thus improve the efficiency of gas turbines.

scholarly journals The effect of changes in depth of cut and cutting speed of CNC toolpaths on turning process performance

2018 ◽  
Vol 38 (1) ◽  
pp. 40-44
Author(s):  
Krzysztof Jarosz ◽  
Piotr Niesłony ◽  
Piotr Löschner
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Process Performance ◽  
Turning Process ◽  
Machining Time ◽  
Toolpath Optimization ◽  
The Impact

Abstract In this article, a novel approach to computer optimization of CNC toolpaths by adjustment of cutting speed vcand depth of cut apis presented. Available software works by the principle of adjusting feed rate on the basis of calculations and numerical simulation of the machining process. The authors wish to expand upon this approach by proposing toolpath optimization by altering two other basic process parameters. Intricacies and problems related totheadjustment of apand vcwere explained in the introductory part. Simulation of different variant of the same turning process with different parameter values were conducted to evaluate the effect of changes in depth of cut and cutting speed on process performance. Obtained results were investigated on the account of cutting force and tool life. The authors have found that depth of cut substantially affects cutting force, while the effect of cutting speed on it is minimal. An increase in both depth of cut and cutting speed affects tool life negatively, although the impact of cutting speed is much more severe. An increase in depth of cut allows for a more significant reduction of machining time, while affecting tool life less negatively. On the other hand, the adjustment of cutting speed helpsto reduce machining time without increasing cutting force component values and spindle load.

Integration of Wireless Sensors and Models for a Smart Machining System

2009 ◽  
Author(s):  
Robert B. Jerard ◽  
Barry K. Fussell ◽  
Chris A. Suprock ◽  
Yanjun Cui ◽  
Jeffrey Nichols ◽  
...  
Keyword(s):  
Low Cost ◽  
Spindle Motor ◽  
Vibration Sensor ◽  
Machining Process ◽  
Sensor Data ◽  
Research Progress ◽  
Force Model ◽  
Calibration Methods ◽  
Machining System ◽  
Smart Machining

This paper describes recent research progress at the University of New Hampshire in the area of “Smart Machining Systems (SMS)”. Our approach to SMS is to integrate models with wireless embedded sensor data to monitor and improve the machining process. This paper discusses recent progress in low-cost wireless sensor development, model calibration methods, model accuracy, and tool condition monitoring for SMS. We describe a system that can estimate tool wear using the coefficients of a tangential cutting force model. The model coefficients are estimated by online measurement of spindle motor power. We also show the use of a cutting tool embedded with a wireless vibration sensor to detect the onset of chatter in real-time.

Evaluation of the Cutting Force and Geometric Error for Roughing Operation by Plunge Milling

2011 ◽  
Vol 223 ◽  
pp. 350-358
Author(s):  
Ivandro Bonetti ◽  
Valter Vander Oliveira ◽  
Adriano Fagali Souza
Keyword(s):  
Cutting Force ◽  
Technological Development ◽  
Cutting Tools ◽  
Axial Direction ◽  
Cutting Parameters ◽  
Geometric Error ◽  
Machining Process ◽  
Plunge Milling ◽  
Machining Time ◽  
Machining Strategies

Nowadays there has been noticeable an expressive technological development in the cutting process to machine moulds and dies, through applying new materials, cutting tools and machining strategies. The rough operations depict an important portion in the machining time of these pieces. In front of this scenario, a new milling rough operation in the tool’s axial direction represents a possibility to optimize this machining process so as decreasing the machining time and increasing the material removes rates. A few scientific studies have been carrying out at this thematic, limited to a technical-commercial researches. Therefore this work contributes with the knowledge in this machining process through an experimental trial analyses. In special it studies the cut direction effects during climb and conventional milling in these operations. The result quantifies the cutting parameters influence at the cutting force and error form.

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