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.

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.

scholarly journals Research and Optimization of Surface Roughness in Milling of SLM Semi-Finished Parts Manufactured by Using the Different Laser Scanning Speed

Materials ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 9 ◽  
Author(s):  
Andrzej Matras
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Laser Scanning ◽  
Cutting Tool ◽  
Scanning Speed ◽  
Milling Process ◽  
Face Milling ◽  
Machining Parameters ◽  
The Face ◽  
Laser Scanning Speed

The paper studies the potential to improve the surface roughness in parts manufactured in the Selective Laser Melting (SLM) process by using additional milling. The studied process was machining of samples made of the AlSi10Mg alloy powder. The simultaneous impacts of the laser scanning speed of the SLM process and the machining parameters of the milling process (such as the feed rate and milling width) on the surface roughness were analyzed. A mathematical model was created as a basis for optimizing the parameters of the studied processes and for selecting the sets of optimum solutions. As a result of the research, surface with low roughness (Ra = 0.14 μm, Rz = 1.1 μm) was obtained after the face milling. The performed milling allowed to reduce more than 20-fold the roughness of the SLM sample surfaces. The feed rate and the cutting width increase resulted in the surface roughness deterioration. Some milled surfaces were damaged by the chip adjoining to the rake face of the cutting tool back tooth.

scholarly journals FPGA Based Real Time Simulations of the Face Milling Process

IEEE Access ◽  
2020 ◽  
Vol 8 ◽  
pp. 215987-216002
Author(s):  
Michal R. Mazur ◽  
Marek A. Galewski ◽  
Krzysztof J. Kalinski
Keyword(s):  
Real Time ◽  
Milling Process ◽  
Face Milling ◽  
The Face ◽  
Real Time Simulations

scholarly journals Analysis of the Face Milling Process Based on the Imitation Modelling

2016 ◽  
Vol 126 ◽  
pp. 012001 ◽  
Author(s):  
V A Khomenko ◽  
A O Cherdancev ◽  
P O Cherdancev ◽  
V D Goncharov ◽  
A Kulawik
Keyword(s):  
Milling Process ◽  
Face Milling ◽  
The Face

Dynamics Modeling-Based Optimization of Process Parameters in Face Milling of Workpieces With Discontinuous Surfaces

2019 ◽  
Vol 141 (10) ◽  
Author(s):  
Guilong Li ◽  
Shichang Du ◽  
Delin Huang ◽  
Chen Zhao ◽  
Yafei Deng
Keyword(s):  
Surface Quality ◽  
Optimization Model ◽  
Removal Rate ◽  
Milling Process ◽  
Face Milling ◽  
Processing Efficiency ◽  
Geometric Characteristics ◽  
Chatter Prediction ◽  
The Face ◽  
Free Material

Abstract Face milling is widely used in machining processes, aimed at providing workpieces with high surface quality. The chatter generated in face milling could lead to tremendous damage to machine tools, poor machined surface quality, and loss of processing efficiency. Most related researches have been focused on the modeling of spindle dynamics and discretization algorithms for chatter prediction. However, few published articles have taken the geometric characteristics of workpieces into consideration, especially for workpieces with discontinuous surfaces in face milling, which leads to poor accuracy of chatter prediction as well as the waste of processing efficiency. To overcome this shortage, a novel dynamic model for the face milling process is built in this paper, considering the cutting insert engagement based on the geometric characteristics of the workpieces and the tool path. The stability lobe diagrams (SLDs) applicable to workpieces with discontinuous surfaces are constructed. A process parameter optimization model is developed to maximize the chatter-free processing efficiency of the face milling process. The sensitivity analysis is utilized to simplify the objective function, and the genetic algorithm is employed to solve the optimization model. The proposed approach is validated by an experimental case study of an engine block, improving the chatter-free material removal rate by 53.3% in comparison to the classic approach.

Structure Dynamic Modification and Optimization for High-Speed Face Milling Cutter

2004 ◽  
Vol 471-472 ◽  
pp. 663-667 ◽  
Author(s):  
Wei Xiao Tang ◽  
Xing Ai ◽  
H.Y. Wu ◽  
Song Zhang ◽  
H. Jiang
Keyword(s):  
High Speed ◽  
Milling Process ◽  
Face Milling ◽  
Relative Speed ◽  
Structural Dynamic ◽  
High Speed Milling ◽  
Structural Dynamic Modification ◽  
The Face ◽  
Dynamic Modification ◽  
The Stability

Due to the complexity of high-speed milling process by high relative speed and interrupted cutting, the face milling cutters possess the multi-order modes and the vibrating displacements of the cutting edges under each modes affect adversely both the surface roughness and the life of machine/tool system worse than other structures. In order to improve the stability of milling process, this work focuses on the influence of the variables such as structure geometries and constraint conditions on the eigenfrequencies and modeshapes of cutter. As an example, the dynamic characteristics of several face cutters are analyzed and optimized by structural dynamic modification (SDM) techniques.

A Mechanistic Model for the Prediction of the Force System in Face Milling Operations

1984 ◽  
Vol 106 (1) ◽  
pp. 81-88 ◽  
Author(s):  
H. J. Fu ◽  
R. E. DeVor ◽  
S. G. Kapoor
Keyword(s):  
Mechanistic Model ◽  
Polycrystalline Diamond ◽  
Milling Process ◽  
Face Milling ◽  
Workpiece Material ◽  
Material Force ◽  
Force System ◽  
Milling Operations ◽  
The Face ◽  
Casting Aluminum

A mechanistic force system model for the face milling process has been developed and implemented on the computer. The model predicts the force system in face milling over a range of cutting conditions, cutter geometries, workpiece, and process geometries including relative positions of cutter to workpiece, spindle tilt, and runout. Machining tests have been conducted for both fly cuting and multitooth cutting with polycrystalline diamond tools on plain surfaces. The 390 casting aluminum alloy has been used as the workpiece material. Force data from these tests were used to estimate the empirical constants of the mechanistic model and to verify its prediction capabilities. Data bases from flycutting tests have been used to predict forces under multitooth face milling and the results indicate good agreement with observed data from multitooth tests.

Determination of Constitutive Equation Parameters for Face Milling 3-D Simulation via Pressure Bar and Orthogonal Cutting Tests

2012 ◽  
Vol 723 ◽  
pp. 136-142 ◽  
Author(s):  
Sha Liu ◽  
Jian Fu Zhang ◽  
Ping Fa Feng ◽  
Ding Wen Yu ◽  
Zhi Jun Wu
Keyword(s):  
Constitutive Equation ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Material Model ◽  
Milling Process ◽  
Face Milling ◽  
Cutting Process ◽  
Element Analysis ◽  
The Face ◽  
Pressure Bar

Material constitutive equation plays an important role in Finite Element Analysis (FEA) of metal cutting process. This paper proposes a method to obtain parameters for Power Law model of a Japanese type of alloy steel (SCM440H) for 3-D FEA of face milling process, involving pressure bar experiments and orthogonal metal cutting experiments. Since pressure bar test cannot reach the high strain rate occurred in cutting process, orthogonal cutting experiment was combined to obtain parameters for material model. By this method, the ideal parameters for FEA of the face milling process were finally determined. Face milling experiments were performed to verify the accuracy of the model built.

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