Characterization of Cutting Force Induced Surface Shape Variation in Face Milling Using High-Definition Metrology1

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Hai Trong Nguyen ◽  
Hui Wang ◽  
S. Jack Hu
Keyword(s):  
Cutting Force ◽  
Process Monitoring ◽  
Face Milling ◽  
Surface Shape ◽  
Machining Process ◽  
High Definition ◽  
Surface Patterns ◽  
Cutting Processes ◽  
And Control ◽  
The Impact

High-definition metrology (HDM) systems with fine lateral resolution are capable of capturing the surface shape on a machined part that is beyond the capability of measurement systems employed in manufacturing plants today. Such surface shapes can precisely reflect the impact of cutting processes on surface quality. Understanding the cutting processes and the resultant surface shape is vital to high-precision machining process monitoring and control. This paper presents modeling and experiments of a face milling process to extract surface patterns from measured HDM data and correlate these patterns with cutting force variation. A relationship is established between the instantaneous cutting forces and the observed dominant surface patterns along the feed and circumferential directions for face milling. Potential applications of this relationship in process monitoring, diagnosis, and control are also discussed for face milling. Finally a systematic methodology for characterizing cutting force induced surface variations for a generic machining process is presented by integrating cutting force modeling and HDM measurements.

Chacterization of Cutting Force Induced Surface Shape Variation Using High-Definition Metrology

2012 ◽  
Author(s):  
Hai Trong Nguyen ◽  
Hui Wang ◽  
S. Jack Hu
Keyword(s):  
Cutting Force ◽  
Process Monitoring ◽  
Surface Shape ◽  
Machining Process ◽  
Monitoring And Control ◽  
High Definition ◽  
Surface Patterns ◽  
Cutting Processes ◽  
And Control ◽  
The Impact

High-definition metrology (HDM) systems with fine lateral resolution are capable of capturing the surface shape on a machined part that is beyond the scope of measurement systems employed in manufacturing plants today. Such surface shapes can precisely reflect the impact of cutting processes on surface quality. Understanding the cutting processes and the resultant surface shape is vital to identifying opportunities for high-precision machining process monitoring and control. This paper presents modeling and experiments of a face milling process to extract surface patterns from measured HDM data and correlate these patterns with cutting force variation. A relation is established between instantaneous cutting forces and the observed dominant patterns along the feed and circumferential directions. Potential applications of such relationship in process monitoring, diagnosis, and control are also discussed.

scholarly journals The cutting behavior of cortical bone in different bone osten cutting angles and depths of cut

2021 ◽  
Author(s):  
Yuanqiang Luo ◽  
Yinghui Ren ◽  
Yang Shu ◽  
Cong Mao ◽  
Zhixiong Zhou ◽  
...  
Keyword(s):  
Fracture Toughness ◽  
Cutting Force ◽  
Cortical Bone ◽  
Depth Of Cut ◽  
Cutting Angle ◽  
Small Depth ◽  
Proposed Model ◽  
Cutting Processes ◽  
The Impact ◽  
Cutting Path

Abstract Cortical bones are semi-brittle and anisotropic, this brings the challenge to suppress vibration and avoid undesired fracture in precise cutting processes in surgeries. In this paper, we proposed a novel analytical model to represent cutting processes of cortical bones, and we used to evaluate cutting forces and fracture toughness, and investigate the formations of chips and cracks under varying bone osteon cutting angles and depths. To validate the proposed model, the experiments are conducted on orthogonal cuttings over cortical bones to investigate the impact of bone osteon cutting angle and depth on cutting force, crack initialization and growth, and fracture toughness of cortical bone microstructure. The experimental results highly agreed with the prediction by the proposed model in sense that (1) curly, serrated, grainy and powdery chips were formed when the cutting angle was set as 0°, 60°, 90°, and 120°, respectively. (2) Bone materials were removed dominantly by shearing at a small depth of cut from 10 to 50 µm, and by a mixture of pealing, shearing, and bending at a large depth of cut over 100 µm at different cutting orientations. Moreover, it was found that a cutting path along the direction of crack initialization and propagation benefited to suppress the fluctuation of cutting force thus reduce the vibration. The presented model has theoretical and practical significance in optimizing cutting tools and operational parameters in surgeries.

scholarly journals Simulating the effect of depth of cut and feed rate on the force components in face milling

2019 ◽  
Vol 9 (1) ◽  
pp. 65-72
Author(s):  
Mohammad Zaher Akkad ◽  
Felhő Csaba
Keyword(s):  
Feed Rate ◽  
Face Milling ◽  
Depth Of Cut ◽  
Third Wave ◽  
Cutting Depth ◽  
Milling Operation ◽  
The Face ◽  
Force Components ◽  
Cutting Processes ◽  
The Impact

This paper presents a study about the workpiece force components (Fx, Fy, Fz) changes in face milling, which results from changing the depth of cut and the feed rate values. The values of the three force components in the face milling operation were found through the FEA-software AdvantEdge by Third Wave Systems. This program is uniquely intended for modelling of cutting processes. Simulations were carried out within five different cutting depth of cut and feed rate, to compare the obtained values and find out the results of the impact of changes on the three force components.

Multi-Scale Surface Characterization and Control Based High Density Measurements

2014 ◽  
Author(s):  
Xin Weng ◽  
Xiaoning Jin ◽  
Jun Ni
Keyword(s):  
Surface Quality ◽  
Process Monitoring ◽  
Surface Characterization ◽  
Quality Evaluation ◽  
Surface Shape ◽  
Machined Surface ◽  
Multi Scale ◽  
And Control ◽  
Scale Surface ◽  
Machined Surfaces

It is widely observed that today’s engineering products demand increasingly strict tolerances. The shape of a machined surface plays a critical role to the desired functionality of a product. Even a small error can be the difference between a successful product launch and a major delay. Thus, it is important to develop measurement tools to ensure the quality and accuracy of products’ machined surfaces. The key to assessing the quality is robust measurement and inspection techniques combined with advanced analysis. However, conventional Geometrical Dimensioning and Tolerancing (GD&T) such as flatness falls short of characterizing the surface shape. With the advancements in metrology methodology utilizing digital holographic interferometry, large amount of surface data can be captured at high resolution and accuracy without changing platform or technique. This captured High Definition Data (HDD) enables the mining of more valuable information from machined surfaces that most current industry practice cannot achieve in a timely manner. Such new metrology system opens the torrent of observable events at plant floor and increases the transparency of machining processes. This presents great opportunities to characterize machined surface into a new level of details, which can be applied in production quality evaluation and process condition monitoring and control. This research work proposes a framework of a multi-scale surface characterization for surface quality evaluation and process monitoring. Case studies are presented to show how proposed metrics could be applied in surface quality evaluation and process monitoring.

High-Definition Metrology Based Spatial Variation Pattern Analysis for Machining Process Monitoring and Diagnosis

2009 ◽  
Author(s):  
Hui Wang ◽  
Saumuy Suriano ◽  
Liang Zhou ◽  
S. Jack Hu
Keyword(s):  
Spatial Variation ◽  
Process Monitoring ◽  
Spatial Data ◽  
Control Charts ◽  
Pattern Analysis ◽  
Surface Region ◽  
High Definition ◽  
Statistical Process ◽  
Surface Variation ◽  
And Control

Non-contact high-definition measurement technology, such as laser holographic interferometry, makes it feasible to quickly inspect dimensional variation at micron level, providing up to 2 million data points over a surface area of up to 300×300 mm2. Such high-definition metrology (HDM) data contain rich spatial variation information but it is challenging to utilize this information for process monitoring and control. The spatial distribution of the data is in high-dimensional form and may show nonlinear patterns. Conventional statistical process monitoring and diagnostic schemes based on simple test statistics and linear statistical process models are incapable of capturing the complex surface characteristics as reflected by large amounts of spatial data. This paper develops a framework for efficient monitoring of spatial variation in HDM data using principal curves and quality control charts. Since large scale surface variation patterns (caused by fixturing and part bending) may camouflage those in the smaller scale (generally associated with tooling conditions), it is essential to separate the patterns in these scales and monitor them individually. At each scale, process monitoring is implemented in a sequential manner by monitoring the overall spatial features followed by localized variation identification if an out-of-control condition is detected. To examine the overall spatial characteristics, a principal-component-analysis (PCA) filtered principal curve regression is proposed in conjunction with multivariate control charts whereby nonlinear patterns of spatial data are extracted and monitored. When the overall monitoring indicates a problem, the identification of a surface variation change can be achieved through localized monitoring over each surface region based on variogram pattern analysis and control charts. The location of surface region change provides clues for variation source diagnosis. The proposed method is illustrated using simulated HDM data.

An object-oriented architecture for sensorless cutting force feedback for CNC milling process monitoring and control

2010 ◽  
Vol 41 (5) ◽  
pp. 754-761 ◽  
Author(s):  
Roberto Augusto Gómez Loenzo ◽  
Pedro Daniel Alaniz Lumbreras ◽  
René de Jesús Romero Troncoso ◽  
Gilberto Herrera Ruiz
Keyword(s):  
Cutting Force ◽  
Process Monitoring ◽  
Force Feedback ◽  
Object Oriented ◽  
Milling Process ◽  
Cnc Milling ◽  
Monitoring And Control ◽  
Process Monitoring And Control ◽  
And Control

scholarly journals The effect of changes in depth of cut and cutting speed of CNC toolpaths on turning process performance

2018 ◽  
Vol 38 (1) ◽  
pp. 40-44
Author(s):  
Krzysztof Jarosz ◽  
Piotr Niesłony ◽  
Piotr Löschner
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Process Performance ◽  
Turning Process ◽  
Machining Time ◽  
Toolpath Optimization ◽  
The Impact

Abstract In this article, a novel approach to computer optimization of CNC toolpaths by adjustment of cutting speed vcand depth of cut apis presented. Available software works by the principle of adjusting feed rate on the basis of calculations and numerical simulation of the machining process. The authors wish to expand upon this approach by proposing toolpath optimization by altering two other basic process parameters. Intricacies and problems related totheadjustment of apand vcwere explained in the introductory part. Simulation of different variant of the same turning process with different parameter values were conducted to evaluate the effect of changes in depth of cut and cutting speed on process performance. Obtained results were investigated on the account of cutting force and tool life. The authors have found that depth of cut substantially affects cutting force, while the effect of cutting speed on it is minimal. An increase in both depth of cut and cutting speed affects tool life negatively, although the impact of cutting speed is much more severe. An increase in depth of cut allows for a more significant reduction of machining time, while affecting tool life less negatively. On the other hand, the adjustment of cutting speed helpsto reduce machining time without increasing cutting force component values and spindle load.

Investigation of the Impact of Orthogonal Cutting Processes on Nanocrystalline Surface Layer Generation

2013 ◽  
Vol 554-557 ◽  
pp. 2009-2020 ◽  
Author(s):  
Volker Schulze ◽  
Frederik Zanger ◽  
Florian Ambrosy
Keyword(s):  
Grain Size ◽  
Surface Layer ◽  
Cutting Force ◽  
Manufacturing Process ◽  
Orthogonal Cutting ◽  
Work Piece ◽  
Passive Force ◽  
Surface Layers ◽  
Cutting Processes ◽  
The Impact

The present work analyzes the influence of an orthogonal machining process on the generation of nanocrystalline surface layers. Thereby, AISI 4140 is used as work piece material. Metallic parts with a severe nanocrystalline grain refinement in the near-surface area show many beneficial properties. Such surface layers considerably influence the friction and wear characteristics of the work piece in a subsequent usage as design elements working under tribological loads. The focus of this paper is an experimental analysis of a finishing orthogonal cutting operation, carried out with a broaching machine, to generate nanocrystalline surface layers. The influence of process and geometry parameters on the generation of nanocrystalline surfaces is investigated with the aim to massively decrease the grain size in the work piece surface layer. Parameters that are studied and taken into account in the manufacturing process are cutting edge radius rβ, depth of cut h and cutting velocity vc. The cutting edge radius rβ is modified by a drag finishing process. The generation of nanocrystalline surface layers is especially influenced by the design of the uncoated carbide cutting tools. Additionally, cutting force Fc and passive force Fp are determined by a 3-component dynamometer to calculate the relationship between specific cutting force kc and specific passive force kp. The temperature beneath the clearance face is detected by a fiber optic pyrometer. These measurement methods and devices are applied to detect the impact of the most relevant measurement values occurring during machining and causing a drastic reduction of grain size in the surface layer. The evaluation of the manufacturing process is carried out by detailed analyses of the microstructural conditions in the surface layer after processing using a Focused Ion Beam (FIB) system. These material characterizations provide information about the surface engineering concerning the microstructural changes in the surface layer of the work piece due to finishing orthogonal cutting processes.

Computer-aided prediction of polyp histology on white light colonoscopy using surface pattern analysis

Endoscopy ◽  
2018 ◽  
Vol 51 (03) ◽  
pp. 261-265 ◽  
Author(s):  
Cristina Sánchez-Montes ◽  
Francisco Sánchez ◽  
Jorge Bernal ◽  
Henry Córdova ◽  
María López-Cerón ◽  
...  
Keyword(s):  
White Light ◽  
Narrow Band Imaging ◽  
Vision System ◽  
Colorectal Polyp ◽  
Surface Shape ◽  
Surface Pattern ◽  
High Definition ◽  
Cad System ◽  
Computer Aided ◽  
Surface Patterns

Abstract Background This study aimed to evaluate a new computational histology prediction system based on colorectal polyp textural surface patterns using high definition white light images. Methods Textural elements (textons) were characterized according to their contrast with respect to the surface, shape, and number of bifurcations, assuming that dysplastic polyps are associated with highly contrasted, large tubular patterns with some degree of bifurcation. Computer-aided diagnosis (CAD) was compared with pathological diagnosis and the diagnosis made by endoscopists using Kudo and Narrow-Band Imaging International Colorectal Endoscopic classifications. Results Images of 225 polyps were evaluated (142 dysplastic and 83 nondysplastic). The CAD system correctly classified 205 polyps (91.1 %): 131/142 dysplastic (92.3 %) and 74/83 (89.2 %) nondysplastic. For the subgroup of 100 diminutive polyps (≤ 5 mm), CAD correctly classified 87 polyps (87.0 %): 43/50 (86.0 %) dysplastic and 44/50 (88.0 %) nondysplastic. There were no statistically significant differences in polyp histology prediction between the CAD system and endoscopist assessment. Conclusion A computer vision system based on the characterization of the polyp surface in white light accurately predicted colorectal polyp histology.

Modular CNC Design for Intelligent Machining, Part 2: Modular Integration of Sensor Based Milling Process Monitoring and Control Tasks

1996 ◽  
Vol 118 (4) ◽  
pp. 514-521 ◽  
Author(s):  
Y. Altintas¸ ◽  
W. K. Munasinghe
Keyword(s):  
Process Control ◽  
Real Time ◽  
Process Monitoring ◽  
Tool Path ◽  
Position Control ◽  
Milling Process ◽  
Machining Process ◽  
Monitoring And Control ◽  
Process Monitoring And Control ◽  
And Control

Modular integration of sensor based milling process monitoring and control functions to a proposed CNC system architecture is presented. Each sensor based process control algorithm resides in a dedicated processor in the AT bus with a modular software. The CNC system’s motion control module has been designed to accomodate rapid manipulation of feeds, cutting conditions and NC tool path which may be demanded by machining process control modules in real time. Modular integration of adaptive control of cutting forces, tool condition monitoring, chatter detection and suppression tasks are illustrated as examples. The process control and monitoring modules are serviced in the real-time multi-tasking environment within one millisecond time intervals without disturbing the position control system. The paper present constraints and guidelines in designing CNC systems which allow modular integration of user developed real time machining process control and monitoring applications.

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