On a Methodology for Establishing the Machine Tool System Requirements for High-Speed/High-Throughput Machining

1985 ◽  
Vol 107 (4) ◽  
pp. 316-324 ◽  
Author(s):  
R. Komanduri ◽  
J. McGee ◽  
R. A. Thompson ◽  
J. P. Covy ◽  
F. J. Truncale ◽  
...  
Keyword(s):  
Aluminum Alloys ◽  
Machine Tool ◽  
High Throughput ◽  
Machine Tools ◽  
High Speed ◽  
Cutting Speed ◽  
Tool Material ◽  
Higher Power ◽  
Increase Productivity ◽  
System Requirements

This paper presents a methodology for determining the machine tool system requirements for high-speed machining (HSM)/high-throughput machining (HTM). Both technological and economic factors should be considered in the formulation of the model for determining machine tool system requirements. The HSM function model is given here in the form of ICAM-defined (IDEFo) charts with corresponding text. For machining most aluminum alloys, the maximum cutting speed is not limited by tool life, and the technology for high-speed machine tools (spindles, table drives, controls, chip management, and other features) exists today. Therefore, HSM of aluminum alloys can be implemented. Selection of a suitable HSM system involves detailed technological analysis and economic justification for a given part-family production configuration. The recent introduction of Si3N4 based tool materials has enabled significantly higher cutting speeds (up to 1524 mpm or 5000 sfpm) in the machining of gray cast iron. However, the machine tools using this type of tool material should be more rigid and capable of higher power, higher speed, and faster feed in order to increase productivity and reduce manufacturing costs. In the machining of the difficult-to-machine materials (e.g., superalloys), the cutting speed is still limited by tool wear. Nevertheless, a high-throughput machining (HTM) strategy is pertinent for this application.

Friction Characteristics of Clasp Locked Precision Locknuts under Different Conditions

2013 ◽  
Vol 853 ◽  
pp. 447-452
Author(s):  
Chih Ming Chen ◽  
Cheng Ho Chen
Keyword(s):  
Mechanical Properties ◽  
Machine Tool ◽  
Product Design ◽  
Data Base ◽  
Machine Tools ◽  
High Speed ◽  
Cutting Speed ◽  
Surface Machining ◽  
Detection Technology ◽  
Cutting Speeds

As the machine tool industry moves towards high speed and high precision, we must have detection technology for the mechanical properties of fasteners, in order to overcome technical bottlenecks. This article is especially aimed at machine tools and special-purpose machines that commonly use clasp locking precision locknuts. In this research, the anti-loosening characteristics of precision nuts are investigated under different conditions, such as the clearances, end processing methods, nut cutting speeds, lubricants, and tightening speeds. The results can provide the precision nut manufacturers a data base for product design. The experimental results show that with the end surface machining method using concentric grinding, nut cutting speed 800rpm, 2rpm speed of tightening, and the use of lubricant 2TML, the nut has better anti-loosening characteristics.

A Technique for Enhancing Machine Tool Accuracy by Transferring the Metrology Reference From the Machine Tool to the Workpiece

2006 ◽  
Vol 129 (3) ◽  
pp. 636-643 ◽  
Author(s):  
Bethany A. Woody ◽  
K. Scott Smith ◽  
Robert J. Hocken ◽  
Jimmie A. Miller
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
High Speed ◽  
Large Scale ◽  
Thermal Environment ◽  
Coordinate Measuring Machine ◽  
Shop Floor ◽  
Finished Part ◽  
Measuring Machine ◽  
Monolithic Components

High-speed machining (HSM) has had a large impact on the design and fabrication of aerospace parts and HSM techniques have been used to improve the quality of conventionally machined parts as well. Initially, the trend toward HSM of monolithic parts was focused on small parts, where existing machine tools have sufficient precision to machine the required features. But, as the technology continues to progress, the scale of monolithic parts has continued to grow. However, the growth of such parts has become limited by the inability of existing machines to achieve the tolerances required for assembly due to the long-range accuracy and the thermal environment of most machine tools. Increasing part size without decreasing the tolerances using existing technology requires very large and very accurate machines in a tightly controlled thermal environment. As a result, new techniques are needed to precisely and accurately manufacture large scale monolithic components. Previous work has established the fiducial calibration system (FCS), a technique, which, for the first time provides a method that allows for the accuracy of a coordinate measuring machine (CMM) to be transferred to the shop floor. This paper addresses the range of applicability of the FCS, and provides a method to answer two fundamental questions. First, given a set of machines and fiducials, how much improvement in precision of the finished part can be expected? And second, given a desired precision of the finished part, what machines and fiducials are required? The achievable improvement in precision using the FCS depends on a number of factors including, but not limited to: the type of fiducial, the probing system on the machine and CMM, the time required to make a measurement, and the frequency of measurement. In this paper, the sensitivity of the method to such items is evaluated through an uncertainty analysis, and examples are given indicating how this analysis can be used in a variety of cases.

scholarly journals Deformation Structures and Tool Wear during High-Speed Machining

2013 ◽  
Vol 10 (1) ◽  
pp. 12-17
Author(s):  
Karol Vasilko
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Tool Material ◽  
Machining Process ◽  
Surface Dynamics ◽  
Machined Surface ◽  
Deformation Structures ◽  
Cutting Speeds ◽  
Tool Durability

Abstract Tendencies towards increasing cutting speeds during machining can be observed recently. The first wave of increasing cutting speeds occured in the 60s of the previous century. However, suitable tool material was not available at that time. Increasing cutting speed is possible only following the development of cutting material, resistant against high temperatures, abrasive, adhesive and diffusive wear. It is obvious that the process of chip creation, quality of machined surface, dynamics of machining process and temperature of cutting change considerably with cutting speed. To be able to apply higher cutting speeds in production machining, it is necessary to know the dependence of those characteristics on cutting speed. Some of those phenomena, which are linked with cutting speed, will be explained in the paper. Key words: machining, cutting speed, tool durability, surface quality

Optimized Design and Performance Study of High Speed Five-Axis Machine Tools

2020 ◽  
Author(s):  
Tzu-Chi Chan ◽  
Jyun-Sian Yang
Keyword(s):  
Machine Tool ◽  
Dynamic Characteristics ◽  
Machine Tools ◽  
High Speed ◽  
Spectral Response ◽  
Work Piece ◽  
Static And Dynamic Characteristics ◽  
Five Axis ◽  
Speed Accuracy ◽  
Machine Structure

Abstract With the development of machine tools trending toward high precision, intelligence, multi-axis, and high speed, the improvement of the processing performance and rigidity of the machine is considerably important. The objective of this study is to design of a high-speed five-axis moving-column machine tool and perform structural analysis and optimization. We study the static and dynamic characteristics of the five-axis machine tool, design and improve the mechanical structure, and optimize the structural configuration of the machine. The entire machine structure is further analyzed and enhanced to improve its static and dynamic characteristics, including static rigidity, modal, transient, and spectral response characteristics. The static and dynamic characteristics of the machine structure directly affect the machine processing performance, and further affect the work piece precision machined by the tool. Through this study, the design technology for speed, accuracy, and surface roughness of the machine tool are further improved.

Study on High-Speed Drilling of SUS304 Based on FEA

2011 ◽  
Vol 188 ◽  
pp. 529-534 ◽  
Author(s):  
M.P. Yan ◽  
H. Shao
Keyword(s):  
Finite Element Analysis ◽  
Tool Wear ◽  
Machine Tools ◽  
High Speed ◽  
Cutting Speed ◽  
Formation Processes ◽  
Element Analysis ◽  
High Speed Drilling ◽  
Tool Wear Mechanism ◽  
Drilling Conditions

Experimental explorations for optimal cutting conditions on high speed drilling processes could be expensive and risky both to machine tools and operators. In this study, high-speed drilling of SUS304 stainless steel with a TiN-coated drill was simulated for optimized drilling conditions. Tool wear mechanism as well as chip formation processes was also explored based on finite element analysis (FEA). It was found with the simulations that higher cutting speed came up with smaller tool wear.

An Investigation on Vibration and Thermal Change of High Speed Lathe Processing Using Infrared Thermal Imaging Technique

2010 ◽  
Vol 123-125 ◽  
pp. 819-822 ◽  
Author(s):  
Yong Ha Yang ◽  
Seung Hyun Choi ◽  
Jae Yeol Kim ◽  
Yong Hoon Cha
Keyword(s):  
Heat Source ◽  
Machine Tool ◽  
Machine Tools ◽  
High Speed ◽  
Internal Heat ◽  
Internal Heat Source ◽  
Infrared Thermal Imaging ◽  
Thermal Change ◽  
Bearing Defects ◽  
Thermal Changes

Vibrations during lathe machining include vibrations by a sudden clash of a tool against a workpiece as an external excitation, vibrations by irregular tissues of the workpiece, vibrations by regular excitation due to asymmetric torque, and vibrations by bearing defects. Furthermore, machine tools are heated because most of the supplied energy is transformed to heat and becomes the heat source of the machine tool or an internal heat source. In addition, the spindle is one of the largest internal heat sources. The heat distortion of the spindle by this heat source has the most serious effect on the total heat distortion of the machine tool, and the heat distortion of machine tools is the largest cause of the degradation of cutting precision. In order to obtain accurate data about the causes of such vibrations and heat, this study measured the vibrations and thermal changes of each specimen using a vibrometer and an infrared thermography camera.

Application of Sandwich-Based Designs on Main Structural Parts of Machine Tools

2011 ◽  
Author(s):  
Jan Smoli´k ◽  
Viktor Kuli´sˇek ◽  
Miroslav Janota
Keyword(s):  
Machine Tool ◽  
Machine Tools ◽  
High Speed ◽  
High Performance ◽  
Transportation Industry ◽  
Static Stiffness ◽  
Modal Damping ◽  
Machine Tool Structures ◽  
Structural Parts

New, higher and challenging properties of new high-speed machines and high-performance machines bring up many questions connected to the design and properties of the main machine tool structures. Parameters like static stiffness, eigenfrequencies, modal damping and mass of parts may be identified as very important, and all these properties need to be improved. The most important material properties in the field of machine tools are presented in this paper. A case study based on a modification of a real horizontal machining centre is introduced. The modification consists in using a sandwich design concept in the main structural machine tool part. The sandwich concept, widely known and used in the aerospace industry and, more generally, the transportation industry, is not commonly used in machine tool design. A significant reduction of mass has been achieved by manufacturing a hybrid column with aluminum foam cores, while static stiffness has not been affected.

Materials Formation Mechanism and Experimental Verification of Micron Long Fiber

2011 ◽  
Vol 179-180 ◽  
pp. 49-54
Author(s):  
Chun Mei Yang ◽  
Yan Ma
Keyword(s):  
High Speed ◽  
Grip Force ◽  
Pure Shear ◽  
Wood Fiber ◽  
Cutting Speed ◽  
Tool Material ◽  
Reducing Power ◽  
Improved Method ◽  
High Speed Cutting ◽  
Wood Grain

In the paper the theory of cutting wood fiber on micron-level has been put forward, that is the cutting power of micron flake wood fiber is much smaller than the mechanical power consumed by grinding. Therefore, the manufacture method for micron flake wood fiber is a kind of way of materials preparation, which can economize energy, decrease in consumption and pollution. From the theoretical analysis, only a reasonable cutting-arrangement on direction can significantly reduce the power. So in the condition of reducing power, relying on pure shear to fracture fibers in tissue is the best effort, at the same time through the vertical ultra-high-speed cutting in grain, the micron filament fibers will be cut out. The influences produced by various factors for the formation of flake fibers have been verified through testing, including the improved tool material, the wood grain, the cutting speed and the improvements for locating specimen.Through the improved method for sluggish wood-fiber cutting, not only does this method reduce power consumption, but also decrease the probability of fiber cut off and substantial increase fiber’s length and quality. Moreover, after these flake fibers having been rescheduled, the elastic modulus of fiber MHFB hot pressed out can reach 5171Mpa, and the grip force of that can reach 1933N.

scholarly journals A Comparison of the Geometrical Accuracy of Thin-Walled Elements Made of Different Aluminum Alloys

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7242
Author(s):  
Magdalena Zawada-Michałowska ◽  
Paweł Pieśko ◽  
Jerzy Józwik ◽  
Stanisław Legutko ◽  
Leon Kukiełka
Keyword(s):  
Aluminum Alloys ◽  
High Speed ◽  
Construction Materials ◽  
Cutting Speed ◽  
Strength Properties ◽  
Structural Elements ◽  
High Speed Cutting ◽  
Geometrical Accuracy ◽  
Thin Walled ◽  
Cutting Speeds

In modern constructions, especially aircraft, the aim is to minimize the weight of the components used. This necessitates the use of innovative construction materials, or the production of these parts with ever-decreasing wall thicknesses. To simplify assembly and improve strength properties, so-called structural elements are being used in the form of monolithic elements, which are replacing the assemblies of parts joined by, for example, riveting. These structures often have a complex, thin-walled geometry with deep pockets. This paper attempts to assess the accuracy of manufacturing thin-walled elements, in the shape of walls with different geometries, made of various aluminum alloys. Machining tests were conducted at different cutting speeds, which allowed comparisons of the geometric accuracy of parts manufactured under conventional and high-speed cutting conditions. Based on the result obtained, it was found that the elements made of EN AW-7075 T651 alloy underwent the greatest deformations during machining in comparison to that of other two materials (EN AW-6082 T651 and EN AC-43000). An increase in the geometrical accuracy of the manufactured elements was also observed with the increase in the cutting speed for the HSC range. Hence, to minimize the postmachining deformation of thin-walled elements, the use of high-speed cutting is justified.

Modern Metals Machining Technology

1966 ◽  
Vol 88 (1) ◽  
pp. 65-71 ◽  
Author(s):  
Robert L. Vaughn
Keyword(s):  
Titanium Alloys ◽  
High Speed ◽  
Metal Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Tool Material ◽  
Cutting Fluid ◽  
Tool Geometry ◽  
Cutter Life ◽  
Cutting Operation

Titanium alloys such as A-110AT, B-120VCA, C-120AV, and 6-6-2AVT, which have been used to manufacture structural components for the aerospace industry, are difficult to machine when compared to aluminum and even some steel alloys. Tool wear for high-speed tool steel and carbide cutters takes place rapidly, necessitating the use of low cutting speeds and feeds to obtain a reasonable cutter life. In this study, the means used toward achieving an objective of increased producibility and reduced costs for titanium alloys was through an intensive machinability investigation of the machining characteristics. Control of pertinent machining variables, such as cutting speed, feed rate, tool material, tool geometry, machine tool setup, and cutting fluid, was rigorously maintained. Comparative cost analyses of the actual cutting operation and the attendant cutting tool costs were made concurrently with the study to obtain conditions which provided the best metal removal rate with reasonable cutter life at the lowest cost.

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