scholarly journals Vibration Diagnosis and Prognostics of Turn-milling Operations using HSS and Carbide End Mill Cutters

2016 ◽  
Vol 23 ◽  
pp. 217-224 ◽  
Author(s):  
K. Arun Vikram ◽  
Ch. Ratnam ◽  
K. Sankar Narayana
Keyword(s):  
End Mill ◽  
Milling Operations ◽  
Turn Milling

Stability of Milling Operations With Asymmetric Cutter Dynamics in Rotating Coordinates

2016 ◽  
Vol 138 (8) ◽  
Author(s):  
Alptunc Comak ◽  
Orkun Ozsahin ◽  
Yusuf Altintas
Keyword(s):  
Time Domain ◽  
Machine Tools ◽  
High Speed ◽  
End Mill ◽  
Spindle Shaft ◽  
Milling Operations ◽  
Stability Model ◽  
Principal Directions ◽  
The Stability ◽  
Rotating Coordinates

High-speed machine tools have parts with both stationary and rotating dynamics. While spindle housing, column, and table have stationary dynamics, rotating parts may have both symmetric (i.e., spindle shaft and tool holder) and asymmetric dynamics (i.e., two-fluted end mill) due to uneven geometry in two principal directions. This paper presents a stability model of dynamic milling operations with combined stationary and rotating dynamics. The stationary modes are superposed to two orthogonal directions in rotating frame by considering the time- and speed-dependent, periodic dynamic milling system. The stability of the system is solved in both frequency and semidiscrete time domain. It is shown that the stability pockets differ significantly when the rotating dynamics of the asymmetric tools are considered. The proposed stability model has been experimentally validated in high-speed milling of an aluminum alloy with a two-fluted, asymmetric helical end mill.

Modeling of Cutting Process with Cutter Axis Inclination

2011 ◽  
Vol 223 ◽  
pp. 66-74 ◽  
Author(s):  
Takashi Matsumura
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Cutting Process ◽  
Mechanistic Models ◽  
End Mill ◽  
High Quality ◽  
Ball End Mill ◽  
Milling Operations ◽  
Edge Roughness

Multi-axis controlled machining has been increasing with the demand for high quality in mold manufacturing. The cutter axis inclination should be properly determined in the milling operations. The paper discusses the cutting process of ball end mill with the cutter axis inclination. Two mechanistic models are presented to show the effect of the cutter axis inclination on the tool wear and the surface finish. The actual cutting time during a rotation of the cutter reduces with increasing the cutter axis inclination. Then, the tool is cooled in the non-cutting time. The tool wear is suppressed with reducing the cutting temperature. The surface finish is also improved by increasing cutting velocities with the cutter axis inclination. When the cutter is inclined in the feed direction, the effect of the edge roughness on the surface finish is eliminated. The discussion based on the simulation is verified in the cutting tests for brittle materials.

scholarly journals Virtual Simulation of Turn-Milling Operations in Multitasking Machines

2012 ◽  
Author(s):  
A. Calleja ◽  
A. Fernandez ◽  
A. Rodriguez ◽  
L.N. Lopez de Lacalle
Keyword(s):  
Virtual Simulation ◽  
Milling Operations ◽  
Turn Milling

scholarly journals Virtual Simulation of Turn-Milling Operations in Multitasking Machines

2011 ◽  
pp. 1235-1236
Author(s):  
Amia Calleja ◽  
Asier Fernandez Valdivielso ◽  
Luis Norberto Lopez de Lacalle ◽  
Jokin Tomas Fernandez
Keyword(s):  
Virtual Simulation ◽  
Milling Operations ◽  
Turn Milling

Dynamics and Stability of Turn-Milling Operations With Varying Time Delay in Discrete Time Domain

2018 ◽  
Vol 140 (10) ◽  
Author(s):  
Alptunc Comak ◽  
Yusuf Altintas
Keyword(s):  
Time Domain ◽  
Chip Thickness ◽  
Body Motion ◽  
Depth Of Cut ◽  
Time Varying Delay ◽  
Milling Operations ◽  
Varying Time Delay ◽  
The Stability ◽  
Five Axis ◽  
Turn Milling

Turn-milling machines are widely used in industry because of their multifunctional capabilities in producing complex parts in one setup. Both milling cutter and workpiece rotate simultaneously while the machine travels in three Cartesian directions leading to five axis kinematics with complex chip generation mechanism. This paper presents a general mathematical model to predict the chip thickness, cutting force, and chatter stability of turn milling operations. The dynamic chip thickness is modeled by considering the rigid body motion, relative vibrations between the tool and workpiece, and cutter-workpiece engagement geometry. The dynamics of the process are governed by delayed differential equations by time periodic coefficients with a time varying delay contributed by two simultaneously rotating spindles and kinematics of the machine. The stability of the system has been solved in semidiscrete time domain as a function of depth of cut, feed, tool spindle speed, and workpiece speed. The stability model has been experimentally verified in turn milling of Aluminum alloy cut with a helical cylindrical end mill.

Investigation of Temperature Distribution in High-Speed End Mill Assisted by Heat Pipe Cooling

2011 ◽  
Vol 418-420 ◽  
pp. 1154-1157
Author(s):  
Qing Hua Song ◽  
Hua Wei Ju ◽  
Wei Xiao Tang
Keyword(s):  
Experimental Study ◽  
Temperature Field ◽  
Heat Pipe ◽  
High Speed ◽  
Experimental Studies ◽  
Solid Cylinder ◽  
End Mill ◽  
Milling Operations ◽  
Cylinder Model ◽  
Pipe Mill

A combined numerical and experimental study is performed to analyze the feasibility of using heat pipe cooling in milling applications. In this model, it is assumed that the end mill is subjected to a static heat source which verifies the analysis and feasibility of using heat pipe cooling in milling operations. The performance of heat pipe mill model is approximated using a solid cylinder model of pure conduction. Both the numerical and experimental studies show that the use of a heat pipe in a mill can reduce the temperature field significantly.

Micro Milling on Thin Wire

2017 ◽  
Vol 749 ◽  
pp. 81-86
Author(s):  
Masaki Serizawa ◽  
Takashi Matsumura
Keyword(s):  
Cutting Forces ◽  
Micro Milling ◽  
End Mill ◽  
Thin Wires ◽  
Feed Direction ◽  
Surface Finishes ◽  
Milling Operations ◽  
Fine Surface ◽  
Clamping System ◽  
Scale Structures

Micro milling is discussed to fabricate micro-scale structures on titanium alloy thin wires. A machine tool was developed to conduct the milling operations with improving the clamping stiffness. A 0.3 mm diameter wire inserted into polyurethane tubes was clamped on an R-shaped groove on the machine table. The cutting tests were conducted with or without the polyurethane tube support. The machining shapes, the surface finishes and the cutting forces were measured to verify the effect of the polyurethane tube and machine table clamping system on stability in the cutting process. The groove direction is out of the feed direction of the end mill without the polyurethane tube support. The micro grooves are machined properly with a fine surface in the feed direction with the support. The cutting forces change periodically with the cutting thickness and the rotation of the cutter in milling. Non-symmetric grooves are also machined with the developed clamping system.

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