A Model-Based Monitoring and Fault Diagnosis Methodology for Free-Form Surface Machining Process

2003 ◽  
Vol 125 (3) ◽  
pp. 397-404 ◽  
Author(s):  
Rixin Zhu ◽  
Richard E. DeVor ◽  
Shiv G. Kapoor
Keyword(s):  
Fault Diagnosis ◽  
Power Distribution ◽  
Process Model ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Free Form ◽  
Surface Machining ◽  
Model Based ◽  
Free Form Surface

In this paper, a process model-based approach has been proposed for monitoring and fault diagnosis in the multi-axis ball end milling process. Besides its ability to deal with complex cutting geometry in free-form surface machining, the method has the capability of not only detecting the presence but also estimating the magnitudes of faults, which include flute chipping, breakage and spindle/cutter axes runout. A threshold-based fault detection method is developed based on the analysis of harmonic power distribution in the cutting force signal. A genetic algorithm approach is used to search and determine the fault pattern and magnitudes. The new approach is validated through both constant cross-section cut and free-form surface machining tests on 1018 steel.

Study on Modeling of Digital Machining Process and its Condition Monitoring & Diagnosis Method

2011 ◽  
Vol 411 ◽  
pp. 622-625
Author(s):  
Hong Rui Cao ◽  
Bing Li ◽  
Zheng Jia He
Keyword(s):  
Fault Diagnosis ◽  
Condition Monitoring ◽  
Process Model ◽  
End Milling ◽  
Surface Shape ◽  
Machining Process ◽  
Error Surface ◽  
Diagnosis Method ◽  
Cnc End Milling ◽  
Digital Machining

Based on a cutting dynamics model, a new digital machining process model that integrates workpiece quality and machining condition information is proposed, and the mapping relationship between machine tool structural dynamics and product quality information (e.g., dimension error, surface shape) is analyzed in detail. On the basis of the digital machining process model, the condition monitoring and fault diagnosis method of the machining process is investigated, and an implementation flowchart of the method is proposed with explanations of critical techniques. Finally, the proposed model is applied to the condition monitoring and fault diagnosis of the machining process of a CNC end milling machine. The damage of its spindle bearing is detected successfully, which provides the proof for the root cause identification of machining error in the digital machining process.

Model Based Feedrate Scheduling for Free-Form Surface Machining

2010 ◽  
Vol 4 (3) ◽  
pp. 273-283 ◽  
Author(s):  
Yaman Boz ◽  
◽  
Onur Demir ◽  
Ismail Lazoglu
Keyword(s):  
Threshold Value ◽  
Free Form ◽  
Machining Processes ◽  
Surface Machining ◽  
Scheduling Strategy ◽  
Model Based ◽  
Feedrate Scheduling ◽  
Deflection Analysis ◽  
Free Form Surface ◽  
Free Form Surfaces

Free-form surfaces are commonly used in the automotive, aerospace, biomedical, home appliance, and die/mold industries. Minimizing cycle times is crucial for free-form surface machining in today’s competitive market. Although there have been remarkable enhancements in the CAD/CAM industry, these enhancements lack physical insight into machining processes. This article presents a model-based feedrate scheduling strategy for 3-axis machining of free-form surfaces. In feedrate scheduling strategy, cycle time is minimized by off-line control of cutting forces under a threshold value between specified feedrate values. Using tool deflection analysis, surface form error can also be predicted. The proposed approaches are tested under various machining conditions and the results are presented in the paper.

scholarly journals Optimization of free-form surface machining using parallel planes strategy and torus milling cutter

2016 ◽  
Vol 232 (2) ◽  
pp. 240-250 ◽  
Author(s):  
Jean-Max Redonnet ◽  
Alejandro Gamboa Vázquez ◽  
Alberto Traslosheros Michel ◽  
Stéphane Segonds
Keyword(s):  
End Milling ◽  
Free Form ◽  
End Mill ◽  
Machining Time ◽  
Surface Machining ◽  
End Mills ◽  
Free Form Surface ◽  
Optimization Methodology ◽  
Free Form Surfaces ◽  
Industrial Part

Machining by parallel planes is a widely used strategy for end-milling of free-form surfaces on 3-axis numerically controlled machines. In industry, this type of machining is generally performed with a hemispherical tool. However, numerous studies have shown the benefits of torus-end mills over ball-end or flat-end mills. More than anything, the machining direction has much influence on productivity while using a torus-end mill. In this context, the choice of the machining direction is of paramount importance when using a torus-end mill in the machining of free-form surfaces. This paper presents an optimization of part machining direction allowing the machining time to be minimized while respecting the maximum imposed scallop height. This optimization methodology is then applied to an industrial part and measurements are performed on this part. The study highlights the interest of optimizing the machining direction and the benefits that can be drawn with respect to machining using a non-optimized direction.

An Approach to Generate Three Dimensional Machining Process Model According to Information from Design Model Based on Definition

2016 ◽  
Vol 693 ◽  
pp. 1684-1692 ◽  
Author(s):  
Hong Lei Zhang ◽  
Wen He Liao ◽  
Yu Guo ◽  
Wen An Yang
Keyword(s):  
Process Model ◽  
Three Dimensional ◽  
Design Model ◽  
Machining Process ◽  
Model Generation ◽  
Geometric Models ◽  
Model Based

Faced with the problem of generation for 3D machining process model, an approach to generate three dimensional machining process model according to information from design model based on definition is proposed. Compared with the existing methods, the approach utilizes multiple information of design model based on definition and takes many phases into consideration of 3D process model generation. The structure of 3D machining process model is defined and the course of 3D process model generation is researched, including multiple information acquirement, generation of procedure geometric models and annotation. Finally, the framework of system and application for 3D machining process model generation are presented for validation purposes.

Tool Path Generation for Five-Axis Controlled Machining of Free-Form Surface Using Barrel Tool: Control of Contact Point on Cutting Edge

2020 ◽  
Author(s):  
Tomonobu Suzuki ◽  
Koichi Morishige
Keyword(s):  
Tool Path ◽  
Contact Point ◽  
Cutting Edge ◽  
Free Form ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Free Form Surface ◽  
The Cost ◽  
Five Axis

Abstract This study aimed to improve the efficiency of free-form surface machining by using a five-axis controlled machine tool and a barrel tool. The barrel tool has cutting edges, with curvature smaller than the radius, increasing the pick feed width compared with a conventional ball end mill of the same tool radius. As a result, the machining efficiency can be improved; however, the cost of the barrel tool is high and difficult to reground. In this study, a method to obtain the cutting points that make the cusp height below the target value is proposed. Moreover, a method to improve the tool life by continuously and uniformly changing the contact point on the cutting edge is proposed. The usefulness of the developed method is confirmed through machining simulations.

Machining of Carbon Fibre-Reinforced Silicon-Ccarbide Composites

2008 ◽  
Vol 59 ◽  
pp. 51-54 ◽  
Author(s):  
Dirk Biermann ◽  
T. Jansen ◽  
M. Feldhoff
Keyword(s):  
Silicon Carbide ◽  
Carbon Fibre ◽  
Drill Hole ◽  
Free Form ◽  
Surface Machining ◽  
Free Form Surface ◽  
Hole Machining

A growing demand for fibre-reinforced ceramics necessitates effective ways for machining these materials. In this paper, different tool concepts are presented for an efficient machining of carbon fibre-reinforced silicon carbide. Drill hole machining, slot machining and first investigations of free-form surface machining are presented.

scholarly journals A High-Efficiency Impeller Channel Quasi-Triangular Tool Path Planning Method Based on Template Trajectory Mapping

2018 ◽  
Vol 36 (6) ◽  
pp. 1216-1223
Author(s):  
Feiyan Han ◽  
Juan Wei ◽  
Bin Feng ◽  
Wu Zhang
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
Planning Method ◽  
Free Form ◽  
Physical Domain ◽  
Tool Path Planning ◽  
Surface Machining ◽  
Mapping Model ◽  
Trajectory Mapping ◽  
Free Form Surface

The manufacturing technology of an integral impeller is an important indicator for measuring the manufacturing capability of a country. Its manufacturing process involves complex free-form surface machining, a time consuming and error-prone process, and the tool path planning is considered as a critical issue of free-form surface machining but still lacks a systematic solution. In this paper, aiming at the tool path planning of the impeller channel, a quasi-triangular tool path planning method based on parametric domain template trajectory mapping is proposed. The main idea is to map the template trajectory to physical domain by using the mapping model of parametric domain to the physical domain to obtain the actual machining path. Firstly, the trajectory mapping model of parametric domain to physical domain is established using the morphing technique, and the template trajectory mapping method in the parametric domain is given. Secondly, the clean-up boundary of the impeller channel is determined in the parametric domain, and the quasi-triangular template trajectory of the impeller channel is defined. Finally, taking a certain type of impeller as an example, the quasi-triangular tool path of the impeller channel is calculated, and the tool path calculation time of this method is compared with that of the traditional isometric offset method. The result shows that the computational efficiency is improved by 45% with this method, which provides a new method for the rapid acquisition of NC machining tool path for impeller channels. In addition, the simulation and actual machining are carried out, the results show that the shape of actual cutting traces on the surface of the impeller channel is quasi-triangular, showing that this method is effective and feasible.

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