A Geometrical Simulation System of Ball End Finish Milling Process and Its Application for the Prediction of Surface Micro Features

2005 ◽  
Vol 128 (1) ◽  
pp. 74-85 ◽  
Author(s):  
Xianbing Liu ◽  
Masakazu Soshi ◽  
Abhijit Sahasrabudhe ◽  
Kazuo Yamazaki ◽  
Masahiko Mori
Keyword(s):  
Cutting Tool ◽  
Milling Process ◽  
Simulation System ◽  
Machining Parameters ◽  
Machined Surface ◽  
Fundamental Study ◽  
Surface Features ◽  
The Difference ◽  
Five Axis ◽  
Machined Surfaces

Finish milling with a ball end mill is a key process in manufacturing high-precision and complex workpieces, such as dies and molds. Because of the complexity of the milling process, it is difficult to evaluate the microcharacteristics of machined surfaces real time, which necessitates the simulation of the process. In this area, the existing related simulation researches mainly focus on scallop height evaluation, but few have presented a whole picture of the microcharacteristics of milled surfaces. This paper develops a comprehensive simulation system based on a Z-map model for predicting surface topographic features and roughness formed in the finish milling process and studies the effect of machining parameters. The adoption of the discretization concept of the tool’s cutting motion makes it possible to dynamically track the cutting tool-workpiece interaction with the tool movement and to describe the cutting edges-workpiece discrete cutting interaction more realistically and, therefore, the microcharacteristics of the machined surfaces more accurately. Also, the effects of the cutting tool run-out and wear are incorporated into the developed model through modifying the tool center motion and the cutting-edge shape, respectively. As a fundamental study, the tool-swept envelope has been simulated. The developed simulation system is applied to thoroughly study the surface features formed by the 2.5-axis finish milling process. The application for general three-axis machining is discussed. Additionally, this paper studies the effect of the tool inclination, which is the most common characteristic in 3+2- or five-axis milling processes, on the machined surface features. Experiments are carried out to study the milling process and to verify the simulation results. The difference between the simulated and experimental results is discussed, and the reason behind the difference is explored.

Experimental investigation of the influence of cutting parameters on surface quality and on the special characteristics of micro-milled surfaces of hardened steels

2021 ◽  
pp. 095440622110130
Author(s):  
Barnabás Zoltán Balázs ◽  
Márton Takács
Keyword(s):  
Surface Quality ◽  
Surface Profile ◽  
Cutting Parameters ◽  
Relevant Information ◽  
Milling Process ◽  
Micro Milling ◽  
Machined Surface ◽  
Analysis Of Dynamics ◽  
Five Axis ◽  
Coated Carbide

Micro-milling is one of the most essential technologies to produce micro components, but due to the size effect, it has many special characteristics and challenges. The process can be characterised by strong vibrations, relatively large run-out and tool deformation, which directly affects the quality of the machined surface. This paper deals with a detailed investigation of the influence of cutting parameters on surface roughness and on the special characteristics of micro-milled surfaces. Several systematic series of experiments were carried out and analysed in detail. A five-axis micromachining centre and a two fluted, coated carbide micro-milling tool with a diameter of 500 µm were used for the tests. The experiments were conducted on AISI H13 hot-work tool steel and Böhler M303 martensitic corrosion resistance steel with a hardness of 50 HRC in order to gain relevant information of machining characteristics of potential materials of micro-injection moulding tools. The effect of the cutting parameters on the surface quality and on the ratio of Rz/ Ra was investigated in a comprehensive cutting parameter range. ANOVA was used for the statistical evaluation. A novel method is presented, which allows a detailed analysis of the surface profile and repetitions, and identify the frequencies that create the characteristic profile of the surface. The procedure establishes a connection between the frequencies obtained during the analysis of dynamics (forces, vibrations) of the micro-milling process and the characterising repetitions and frequencies of the surface.

Error Analysis by Square 3 x 3 Machining Method for Five-Axis Machining Centers

2020 ◽  
Author(s):  
Shigehiko Sakamoto ◽  
Atsushi Yokoyama ◽  
Kazumasa Nakayasu ◽  
Toshihiro Suzuki ◽  
Shinji Koike
Keyword(s):  
International Standards ◽  
Test Method ◽  
Accuracy Evaluation ◽  
Alignment Error ◽  
Machined Surface ◽  
Machining Center ◽  
Alignment Errors ◽  
Assembly Error ◽  
Five Axis ◽  
Machined Surfaces

Abstract The establishment of international standards for 5-axis control machining centers has been supported by the high interest of each country. Internationally, various accuracy inspection methods have been proposed and widely discussed. Accuracy measuring devices for these purposes have also been proposed. In 2014, inspection methods for 5-axis machines were published in ISO 10791-6 and 10791-7. In this research, we propose a test method to process 9 square faces as a new accuracy evaluation method. We simulate the influence of assembly error by the proposed square 3 × 3 machining method on the machined surface. By processing 9 square faces with different tool angle on the same plane, it was possible to evaluate the influence of assembly errors in the 5-axis machining center on the machined surface. Nine surfaces machined by the square 3 × 3 processing method cause differences in surface height due to alignment errors. In addition, nine machined surfaces become all diagonal not parallelism. The alignment errors of the 5-axis machining center is identified by evaluating the orientation of the machined surfaces. Specifically, we propose a newly method to measure the height difference of nine surfaces. Then, the possibility of identifying the alignment error of the 5-axis machining center using the measurement results is shown.

Synthesis of Cutting Tool Placement, Orientation and Motion Based on Surface Analysis

2000 ◽  
Author(s):  
C. G. Jensen ◽  
J. K. Hill ◽  
K. A. White
Keyword(s):  
Tool Path ◽  
Cutting Tool ◽  
A Priori ◽  
Cutting Tools ◽  
Detection Algorithm ◽  
Detection Methods ◽  
Machined Surface ◽  
Mathematical Basis ◽  
Five Axis ◽  
Verification Techniques

Abstract Engineers and designers use a wide variety of curve and surface formulations to describe products. The process of producing the physical shape of these products has remained essentially unchanged for many years. Traditionally, the process of finish surface machining has been error prone and inefficient due in large part to the mathematical basis used to control the positioning, orientation and movement of cutting tools in five-axis machining centers. This paper presents swept silhouette curvature matching algorithms for positioning and orienting a cutter such that tool and surface curvatures match. Formulations are given for both flat and filleted end mill cutters. The benefits of curvature matching are: reduction of local machining errors, reduction or elimination of grinding of the finished machined surface, and the improvement of machine tool efficiency. Examples are given that compare curvature matching to traditional machining methods. The paper concludes by discussing current research into a priori gouge detection methods based on intersection contact between the cutting tool and the design surface or the lower tolerance-bound offset surface to the design surface. An a priori gouge detection algorithm is necessary for the development of optimal tool motion and the reduction of time spent in tool path editing and verification. Techniques involving collinear normals, Bézier clipping, triangulation, normal intersection and swept volumes are suggested as techniques for examining the positional and translational tool gouge problem.

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.

The Effect of the Cutting Parameters on the Machined Surface Roughness

2017 ◽  
Vol 260 ◽  
pp. 219-226 ◽  
Author(s):  
Viktors Gutakovskis ◽  
Eriks Gerins ◽  
Janis Rudzitis ◽  
Artis Kromanis
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Tool Geometry ◽  
Machining Parameters ◽  
Machined Surface ◽  
Machined Surface Roughness

From the invention of turning machine or lathe, some engineers are trying to increase the turning productivity. The increase of productivity is following after the breakout in instrumental area, such as the hard alloy instrument and resistance to wear cutting surfaces. The potential of cutting speed has a certain limit. New steel marks and cutting surfaces types allow significantly increase cutting and turning speeds. For the most operation types the productivity increase begins from the feeding increase. But the increase of feeding goes together with machined surface result decreasement. Metal cutting with high feeding is one of the most actual problems in the increasing of manufacturing volume but there are some problems one of them is the cutting forces increasement and larger metal removal rate, which decrease the cutting tool life significantly. Increasing of manufacturing volume, going together with the cutting instrument technology and material evolution, such as the invention of the carbide cutting materials and wear resistant coatings such as TiC and Ti(C,N). Each of these coating have its own properties and functions in the metal cutting process. Together with this evolution the cutting tool geometry and machining parameters dependencies are researched. Traditionally for the decreasing the machining time of one part, the cutting parameters were increased, decreasing by this way the machining operation quantity. In our days the wear resistance of the cutting tools increasing and it is mostly used one or two machining operations (medium and fine finishing). The purpose of the topic is to represent the experimental results of the stainless steel turning process, using increased cutting speeds and feeding values, to develop advanced processing technology, using new modern coated cutting tools by CVD and PVD methods. After investigation of the machined surface roughness results, develop the mathematical model of the cutting process using higher values of the cutting parameters.

A Generic Approach to Modeling Geometry of Un-Deformed Chip by Mathematical Representing Envelopes of Swept Cutter in Five-Axis CNC Milling

2014 ◽  
Author(s):  
Zhiyong Chang ◽  
Zezhong C. Chen ◽  
Jie Zhao ◽  
Dinghua Zhang
Keyword(s):  
High Performance ◽  
Machining Parameters ◽  
Interpolation Algorithm ◽  
Cnc Milling ◽  
Machined Surface ◽  
Machine Surface Quality ◽  
Cnc Interpolation ◽  
Five Axis ◽  
Chip Geometry ◽  
Mill Process

To pursue high performance 5-axis CNC milling in industry, it is crucial to simulate each specific mill process in high fidelity beforehand, which should model the machined surfaces and predict the cutting forces in the process planning. However, the kernel technique, representation of the un-deformed chip geometry removed by cutter in 5-axis milling, is far from mature. Aiming to solve the problem, this paper presents a generic approach to representing un-deformed chip geometry mathematically in 5-axis CNC milling. The unique features of this research are: (1) the machine tool kinematics chain is investigated and a 5-axis CNC interpolation algorithm is adopted to establish the tool kinematics model, and (2) the closed-form equation of the un-deformed chip geometry representation is derived based on the machined shape being the envelope of a group of ellipses. This approach can model a machined surface with high accuracy and efficiently, and can be used to evaluate the machine surface quality and machining parameters. It can greatly promote the technique of high performance 5-axis CNC milling.

Dynamics of flexible detail milling

2011 ◽  
Vol 225 (4) ◽  
pp. 299-309 ◽  
Author(s):  
S A Voronov ◽  
I A Kiselev
Keyword(s):  
Milling Process ◽  
Machining Process ◽  
Machined Surface ◽  
Workpiece Surface ◽  
Thin Walled Structures ◽  
Milling Operations ◽  
Efficient Processing ◽  
The Stability ◽  
Five Axis

The five-axis milling operations are commonly used in aerospace industry. For example, this operation is the base for the machining process of the turbine blade production. The milling operations of thin-walled structures cause the vibrations of the tool and the workpiece and this turn affect the quality of the workpiece surface. Modelling of the milling process is necessary to determine the proper cutting conditions for the required productivity and the surface quality. In this article, the geometry modelling algorithm for five-axis milling process is proposed. Dynamics of the machined surface is modelled using the finite-element method. The obtained results make possible to conclude about the stability of milling process and to calculate the efficient processing conditions at which the amplitude of the generated vibrations does not exceed the admissible level. The results of this research can be used while the milling process technologies are designed. Especially, it is significant for the machining of hard-to-machine materials and processing of heat-resistant alloys in space and aircraft industries.

Effect of Milling Parameters and Coolants on Surface Hardness of Tool Steel: SKD 11

2013 ◽  
Vol 650 ◽  
pp. 596-601
Author(s):  
Apichad Inkhamnoi ◽  
Komson Jirapattarasilp
Keyword(s):  
Tool Steel ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Surface Hardness ◽  
Milling Process ◽  
Dry Cutting ◽  
Machined Surface ◽  
Milling Parameters ◽  
The Face

The purpose of this research was to study milling parameters and coolant, which were affecting to surface hardness of tool steel: SKD 11. The experiment was design by conduction of 3 factors and 3 levels. The parameters consisted of three levels of cutting speed and three levels of feed rate. Furthermore, the experiment was done by coolant types. Soluble oil vegetable oil and dry-cutting were used for coolant types in milling. The face milling process was chosen to experiment. Cutting tool was used for this study was inserted carbide with coated polycrystalline vapor deposited (PVD) tools. The finding of main factors and interaction between factors affected to surface hardness was analyzed. Effect of cutting speed and feed rate on surface hardness after milling was discussed. In order to finding suitable of coolant type, effect of coolants on hardness of machined surface was analyzed and compared.

scholarly journals Prediction of machining accuracy based on geometric error estimation of tool rotation profile in five-axis multi-layer flank milling process

2020 ◽  
Vol 234 (11) ◽  
pp. 2160-2177
Author(s):  
Hangzhuo Yu ◽  
Lei Jiang ◽  
Jindong Wang ◽  
Shengfeng Qin ◽  
Guofu Ding
Keyword(s):  
Prediction Model ◽  
Great Influence ◽  
Milling Process ◽  
Geometric Error ◽  
Flank Milling ◽  
Machining Accuracy ◽  
Machined Surface ◽  
Contact Points ◽  
Five Axis ◽  
Tool Rotation

In five-axis multi-layer flank milling process, the geometric error of tool rotation profile caused by radial dimension error and setup error has great influence on the machining accuracy. In this work, a new comprehensive error prediction model considering the inter-layer interference caused by tool rotation profile error is established, which incorporates a pre-existing prediction model dealing with a variety of errors such as geometric errors of machine tool, workpiece locating errors, and spindle thermal deflection errors. First, a series of tool contact points on the tool swept surface in each single layer without overlapping with others are calculated. Second, the position of the tool contact points on the overlapped layers is updated based on the detection and calculation of inter-layer interferences. Third, all evaluated tool contact points on the final machined surface are available for completing the accuracy prediction of the machined surface. A machining experiment has been carried out to validate this prediction model and the results show the model is effective.

Machining Parameters Mapping’s of Inconel 718 and Aluminum Alloy 1100 in Micro-Milling Process

2020 ◽  
Vol 846 ◽  
pp. 99-104
Author(s):  
Gandjar Kiswanto ◽  
Maulana Azmi ◽  
Adrian Mandala ◽  
Dede Lia Zariatin ◽  
Tae Jo Ko
Keyword(s):  
Aluminum Alloy ◽  
Inconel 718 ◽  
Cutting Tool ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Manufacturing Cost ◽  
Machining Parameters ◽  
Workpiece Material

The development of micro-products in industry, like aviation, medical equipment, electronics, etc, has been increasing lately. The need for scaling down of product has been increasing to make the product simpler and complex. Micro-milling has capabilities in producing complex parts. In this study, mapping and comparing the result of the machining process of Inconel 718 and Aluminum Alloy 1100 was employed. In this experiment, Inconel 718 was used as workpiece material and the result of Aluminum Alloy taken from recent studies. Then, A cutting tool with a diameter 1 mm carbide coating TiAlN was used in this experiment. The machining process was performed with three varieties of spindle speed and feed rate with a constant depth of cut. After the machining is done, the mapping of the result surface roughness of Inconel 718 and AA1100 performed. It was found that Inconel 718 has poor machinability compared with AA 1100. Inconel 718 also has a high manufacturing cost compared to AA 1100 because the cutting tool was easy to wear.

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