scholarly journals Mathematical model for determination of the most advantageous conditions for formation of parts of aerospace engineering on the operations of the end milling

2018 ◽  
Vol 224 ◽  
pp. 01111
Author(s):  
Dmitriy L. Skuratov ◽  
Dmitriy V. Evdokimov ◽  
Dmitriy G. Fedorov
Keyword(s):  
Mathematical Model ◽  
Objective Function ◽  
End Milling ◽  
Inequality Constraints ◽  
Milling Process ◽  
Linear Inequality Constraints ◽  
Milling Operations ◽  
Constraint Inequalities ◽  
Cutting Zone

A mathematical model has been introduced for determining the most advantageous conditions for parts formation when end milling operations. This model consists of a linear objective function and linear inequality constraints and takes into account the kinetics of thermal processes in the cutting zone. The equation determines the processing time was used as the objective function and constraint inequalities are related with the functional parameters and the parameters of the milling process and determines the quality of the machining.

scholarly journals Mathematical model for determining rational machining conditions for flat grinding with the wheel periphery on machines with a rectangular table

2018 ◽  
Vol 224 ◽  
pp. 01112
Author(s):  
Dmitriy L. Skuratov ◽  
Dmitriy G. Fedorov ◽  
Dmitriy V. Evdokimov
Keyword(s):  
Mathematical Model ◽  
Objective Function ◽  
Linear Inequality ◽  
Inequality Constraints ◽  
Machining Time ◽  
Functional Parameters ◽  
Linear Inequality Constraints ◽  
Machining Quality ◽  
Machining Conditions ◽  
Grinding Operations

A mathematical model is presented for determining the rational machining conditions for flat grinding operations by the rim of a wheel on machines with a rectangular table consisting of a linear objective function and linear inequality constraints. As the objective function, the equation, determining the main machining time, was used. And constraints which are related to the functional parameters and parameters determining the machining quality and the kinematic capabilities of the machine were used as inequality constraints.

scholarly journals Surface Integrity Investigation to Determine Rough Milling Effects for Assessment of Machining Allowance for Subsequent Finish Milling of Alloy 718

2021 ◽  
Vol 5 (2) ◽  
pp. 48
Author(s):  
Jonas Holmberg ◽  
Anders Wretland ◽  
Johan Berglund ◽  
Tomas Beno ◽  
Anton Milesic Karlsson
Keyword(s):  
Surface Integrity ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Milling Operations ◽  
Milling Operation ◽  
Machining Allowance ◽  
Rough Milling

The planned material volume to be removed from a blank to create the final shape of a part is commonly referred to as allowance. Determination of machining allowance is essential and has a great impact on productivity. The objective of the present work is to use a case study to investigate how a prior rough milling operation affects the finish machined surface and, after that, to use this knowledge to design a methodology for how to assess the machining allowance for subsequent milling operations based on residual stresses. Subsequent milling operations were performed to study the final surface integrity across a milled slot. This was done by rough ceramic milling followed by finish milling in seven subsequent steps. The results show that the up-, centre and down-milling induce different stresses and impact depths. Employing the developed methodology, the depth where the directional influence of the milling process diminishes has been shown to be a suitable minimum limit for the allowance. At this depth, the plastic flow causing severe deformation is not present anymore. It was shown that the centre of the milled slot has the deepest impact depth of 500 µm, up-milling caused an intermediate impact depth of 400 µm followed by down milling with an impact depth of 300 µm. With merged envelope profiles, it was shown that the effects from rough ceramic milling are gone after 3 finish milling passes, with a total depth of cut of 150 µm.

Study on Surface Roughness in Micro End Milling of Mold Material

2011 ◽  
Vol 325 ◽  
pp. 594-599 ◽  
Author(s):  
Hiroo Shizuka ◽  
Koichi Okuda ◽  
Masayuki Nunobiki ◽  
Yasuhito Inada
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Milling Process ◽  
Cutting Conditions ◽  
Mold Material ◽  
Depth Of Cut ◽  
Milling Operations ◽  
Radial Depth ◽  
Micro End Milling ◽  
End Milling Process

The effects of cutting conditions on the surface roughness in a micro-end-milling process of a mold material are described in this paper. Micro-end-milling operations were performed under different cutting conditions such as feed rate and depth of cut, in order to investigate the factors that had the greatest influence on the finished surface during micro-end-milling. It was revealed that the surface roughness begins to deteriorate when the radial depth of the cut exceeds the tool radius. In addition, it was found that this phenomenon is peculiar to micro-end-milling processes.

The Importance of Including Size Effect When Modeling Slot Milling

1998 ◽  
Vol 120 (1) ◽  
pp. 68-75 ◽  
Author(s):  
S. N. Melkote ◽  
W. J. Endres
Keyword(s):  
Size Effect ◽  
Cutting Force ◽  
End Milling ◽  
Helix Angle ◽  
Milling Process ◽  
Depth Of Cut ◽  
Slot Milling ◽  
Milling Operations ◽  
Force Variation ◽  
Axial Depth

This paper presents a detailed mechanistic force analysis that includes size effect for slot milling operations. Existing studies of the milling process have modeled the slot end milling operation as a simple geometric extension of peripheral end milling models with constant values for the specific energies used to predict forces for a given cutter geometry and cutting conditions. This paper addresses the limitations of this approach for accurate predictions of the instantaneous cutting force variation, particularly for steady-state slotting with four-flute cutters. It is shown through a comparison of model simulations and experimental results that significantly improved predictions of the cutting force variation are obtained by properly accounting for the size effect in slotting. The dependence of the cutting force variation on axial depth of cut and helix angle is demonstrated. Practical implications of selecting helix angle and axial depth of cut based on the improved slot end milling model are also discussed. Modeling approaches other than the mechanistic approach considered here are also noted in this light.

scholarly journals Experimental Determination of Dominant Multipliers in Milling Process by Means of Homogeneous Coordinate Transformation

2017 ◽  
Author(s):  
Adam K. Kiss ◽  
Daniel Bachrathy ◽  
Gabor Stepan
Keyword(s):  
Detection Method ◽  
Monodromy Matrix ◽  
Quantitative Measure ◽  
Milling Process ◽  
Chatter Detection ◽  
External Excitation ◽  
Transient Vibration ◽  
Milling Operations ◽  
Dominant Characteristic

In this contribution, a chatter detection method is investigated for milling operations. The proposed approach can give not only qualitative condition (stable or unstable), but a quantitative measure of stability. For this purpose, it requires an external excitation of stable machining condition. Transient vibration of the perturbation is captured by means of stroboscopic section, and the corresponding monodromy operator is approximated by its projection to the subspace of the dominant modes. The monodromy matrix is determined with the application of homogeneous coordinate representation. Then, the periodic solution and the dominant characteristic multipliers are calculated and their modulus determines the quantitative measure of stability condition.

scholarly journals T3D end milling finite element thermal analysis

2018 ◽  
Vol 184 ◽  
pp. 03001
Author(s):  
Andjelija. Mitrović ◽  
Pavel. Kovač ◽  
Nenad. Kulundžić ◽  
Borislav. Savković ◽  
Ildiko. Mankova
Keyword(s):  
Thermal Analysis ◽  
Finite Element ◽  
Software Package ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Work Piece ◽  
Third Wave ◽  
Modern Approach ◽  
Cutting Zone

The paper presents a modern approach to the phenomenon of thermal analysis in end milling by the finite element method. 3D model of the end mill and work-piece was created in the software package SolidWorks. In order to predict the occurrence of thermal phenomena in milling process software package Third Wave AdvatEdge was used. Influence of cutting speed on the temperature in cutting zone was modelled and analyzed.

Investigation on Effect of Machining Parameters of End Milling on Surface Finish and Temperature Using Taguchi Technique

2016 ◽  
Vol 16 (4) ◽  
pp. 255-261
Author(s):  
Tamiloli N ◽  
Venkatesan J
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Milling Process ◽  
Machining Parameters ◽  
Cutting Zone ◽  
Machining Optimization ◽  
Quality Surface

AbstractMachining of alloy materials at high cutting speeds produces high temperatures in the cutting zone, which affects the surface quality. Thus, developing a model for estimating the cutting parameters and optimizing this model to minimize the surface roughness and cutting temperatures becomes utmost important to avoid any damage to the quality surface. This paper presents the development of new models and optimizing these models of machining parameters to minimize the surface roughness and cutting temperature in end milling process by Taguchi method with the statistical approach. Two objectives have been considered, minimum arithmetic mean roughness (Ra) and cutting temperature. Due to the complexity of this machining optimization problem, a single objective Taguchi method has been applied to resolve the problem, and the results have been analyzed.

scholarly journals Evaluation Of Cutting Force in End Milling Process of Aluminum Alloy 6061-T6 Using Tungsten Carbide Inserts with MQL Method Utilizing Hybrid Nanofluid

2021 ◽  
Vol 84 (1) ◽  
pp. 111-125
Author(s):  
Wahaizad Safiei ◽  
Md Mustafizur Rahman ◽  
Ahmad Razlan Yusoff ◽  
Wajiha Tasnim ◽  
Zetty Akhtar Abd Malek
Keyword(s):  
Aluminum Alloy ◽  
Tungsten Carbide ◽  
Cutting Force ◽  
End Milling ◽  
Milling Process ◽  
Working Fluid ◽  
Hybrid Nanofluid ◽  
Cutting Zone ◽  
End Milling Process ◽  
Alloy 6061

As an alternative to conventional metal working fluid in the end milling process, a combination of newly developed tri-hybrid SiO2-Al2O3-ZrO2 in aqueous-based nanofluid was delivered to the cutting zone using the MQL technique. The liquid has excellent thermal-rheology properties that can offer effective cooling and lubricating during the process. The tri-hybrid nanofluid application is environmentally safe, thus promoting sustainable manufacturing compared to the conventional working fluid. In this experimental study, the cutting forces were investigated comprehensively. Tri-hybrid nanofluid presents in atomizing conditions using the minimum quantity lubricant (MQL) technique at the cutting zone. Industrial standard inserts, namely uncoated, CVD TiCN-Al2O3 and PVD TiAlTaN tungsten carbide used in the experiments. End milling process variables were cutting speed, feed rate, depth of cut, MQL flow rate and nanofluid concentrations. The response data were analyzed statistically based on the design of experiment and regression models were developed for each response according to response surface methodology. Higher cutting force was observed at extreme machining parameters, which regards to higher material removal rate. During the cutting process of Aluminum Alloy 6061-T6, the cutting force, Fr measured was between 16 Newton and 30 Newton. The cutting force in Y-axes (Fy) demonstrates a higher magnitude than others due to the cutting feed of AA6061-T6 in the Y direction. CVD TiCN-Al2O3 tungsten carbide exhibited higher cutting force (Fy) due to coated hardness and tool failures mechanism on both rake and flank face as the wear phenomenon will increase the land contact area. In summary, the resultant cutting force (Fr) was recorded below 30 Newton, indicating the significant improvement in the end milling process. For future experimental works, the cutting force can be explored by considering different nanofluids, extreme machining conditions and brittle material.

Dynamics and Stability of Five-Axis Ball-End Milling

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
Erdem Ozturk ◽  
Erhan Budak
Keyword(s):  
Time Domain ◽  
End Milling ◽  
Milling Process ◽  
Ball End Milling ◽  
Part Quality ◽  
Stability Diagrams ◽  
Milling Operations ◽  
The Stability ◽  
Milling Dynamics ◽  
Five Axis

Being one of the most important problems in machining, chatter vibrations must be avoided as they result in high cutting forces, poor surface finish, and unacceptable part quality. Using stability diagrams is an effective method to predict chatter free cutting conditions. Although there have been numerous works in milling dynamics, the stability of five-axis ball-end milling has not been studied in detail. In this paper, the stability of the five-axis ball-end milling is analyzed using analytical (frequency domain), numerical (time-domain), and experimental methods. The models presented consider 3D dynamics of the five-axis ball-end milling process including the effects of all important process parameters such as the lead and tilt angles. Both single- and multi-frequency solutions are presented. Unlike other standard milling cases, it is observed that adding multi-frequency effects in the solution has marginal influence on the stability diagrams for five-axis ball-end milling operations due to effects of the ball-end milling geometry on the engagement region, thus, on the directional coefficients. The stability limits predicted by single- and multi-frequency methods are compared with time-domain simulations and experiments. Using the models and experimental results, the effects of the lead and tilt angles on the stability diagrams are also shown. The presented models can be used in analysis of five-axis ball-end milling dynamics as well as in the selection of the milling conditions for increased stability.

scholarly journals An Analytical Thermomechanical Modelling of Peripheral Milling Process Using a Predictive Machining Theory

2011 ◽  
Vol 223 ◽  
pp. 93-100 ◽  
Author(s):  
Abdelhadi Moufki ◽  
Daniel Dudzinski ◽  
G. Le Coz
Keyword(s):  
End Milling ◽  
Three Dimensional ◽  
Rate Sensitivity ◽  
Milling Process ◽  
Thermomechanical Coupling ◽  
Force Model ◽  
Peripheral Milling ◽  
Inertia Effects ◽  
Milling Operations ◽  
Alternative Approach

In this work, a predictive machining theory, based on an analytical thermomechanical approach of oblique cutting [17,18], has been applied to the peripheral milling process. That leads to a three dimensional cutting force model for end milling operations which is an alternative approach in comparison with the mechanistic one. In this model, the material characteristics such as strain rate sensitivity, strain hardening and thermal softening are considered and thermomechanical coupling and inertia effects are accounted for. Calculated and experimental results are compared for up-milling.

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