Effect of Workpiece Curvature on Axial Surface Error Profile in Flat End-Milling of Thin-walled Components

Hard machinability of titanium alloy material and poor stiffness of thin-walled part restricted the extensive applications of titanium alloy thin-walled component in aerospace engineering. In order to increase geometric accuracy, a method of ultrasonic vibration assisted (UVA) end milling technology with workpiece vibrating in feeding direction was put forward in this paper, and the corresponding milling force characteristics in UVA milling of titanium alloy TC4 thin-walled workpiece were researched. Through theoretical analysis, the path of cutter tooth in UVA milling was analyzed. The important factors that affect milling force are obtained with the signal to noise ratio analysis. Results show that the radial cutting force in UVA milling is smaller than that in traditional milling. Cutting force fluctuate in high frequency when treated ultrasonic vibration. And the axial cutting feed is the core factor that affects the milling force. The research provides a certain reference for the precision milling of titanium alloy thin-walled parts.

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Effect of component configuration on geometric tolerances during end milling of thin-walled parts

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-021-08185-x ◽

2021 ◽

Author(s):

Ankit Agarwal ◽

Kaushal A. Desai

Keyword(s):

End Milling ◽

Geometric Tolerances ◽

Thin Walled

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Rigidity Regulation Approach for Geometric Tolerance Optimization in End Milling of Thin-walled Components

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4051008 ◽

2021 ◽

pp. 1-34

Author(s):

Ankit Agarwal ◽

K A Desai

Keyword(s):

End Milling ◽

Traditional Approach ◽

Force Model ◽

Geometric Tolerances ◽

Novel Approach ◽

Cutting Sequences ◽

Finish Cutting ◽

Thin Walled ◽

Cutting Sequence ◽

Regulation Approach

Abstract The paper presents a novel approach to improve geometric tolerances (flatness and cylindricity) by manipulating the rigidity among finishing and roughing cutting sequences during end milling of thin-walled components. The proposed approach considers the design configuration of the thin-walled component as an input and aims to determine semi-finished geometry such that the geometric tolerances are optimized while performing finish cutting sequence. The objective is accomplished by combining Mechanistic force model, Finite Element (FE) analysis based workpiece deflection model and Particle Swarm Optimization (PSO) technique to determine optimal disposition of material along the length of component thereby regulating rigidity. The algorithm has been validated by determining rigidity regulated semi-finished geometries for thin-walled components having straight, concave and convex configurations. The outcomes of the proposed algorithm are substantiated further by conducting a set of end milling experiments for each of these cases. The results of the proposed strategy are compared with a traditional approach considering no change in the rigidity of component along length of the cut. It is demonstrated that the proposed approach can effectively optimize geometric tolerances for thin-walled components during end milling operation.

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Study of the Effects of Miniaturization on Static and Dynamic Form Errors in Desktop Milling Machines

Volume 4: Design and Manufacturing ◽

10.1115/imece2009-11141 ◽

2009 ◽

Author(s):

Milad Vazirian ◽

Mohammad-Reza Movahhedy ◽

Javad Akbari

Keyword(s):

Machine Tools ◽

End Milling ◽

Small Scale ◽

Milling Machine ◽

Fluid Consumption ◽

Static Deflection ◽

Surface Error ◽

Form Errors ◽

Dynamic Form ◽

Milling Machines

Desktop and miniaturized machine tools are a new trend in small scale and customized manufacturing. The performance of these machines in terms of their energy consumption, machining fluid consumption and their precision have been investigated in the literature, but the effect of miniaturization on static deflection, stability against chatter and the resulting surface error has not been studied. In this paper, the performance of the desktop milling machine tool in terms of their static and dynamic form errors is studied. The performance of a miniature milling machine used for end milling of a typical workpiece is compared with a similar machine of conventional size through dimensional analysis and numerical modeling. The error of the surface finish generated is predicted and verified through simulation.

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