Finite Element Analysis of a Frictionally Damped Slender Endmill

2012 ◽  
Author(s):  
Reza Madoliat ◽  
Sajad Hayati
Keyword(s):  
Finite Element ◽  
End Milling ◽  
Friction Stress ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Parameter Study ◽  
Bending Vibration ◽  
Element Analysis ◽  
Tool Axis

This paper primarily deals with suppression of chatter in end-milling process. Improving the damping is one way to achieve higher stability for machining process. For this purpose a damper is proposed that is composed of a core and a multi fingered hollow cylinder which are shrink fitted in each other and their combination is shrink fitted inside an axial hole along the tool axis. This structure causes a resisting friction stress during bending vibration. Using FEA-ANSYS the structure is simulated. Then a parameter study is carried out where the frequency response and the depth of cut are calculated and tabulated to obtain the most effective configuration. The optimal configuration of tool is fabricated and finite element results are validated using modal test. The results show a high improvement in performance of the tool with proposed damper. Good agreement between experiments and modeling is obtained.

Finite Element Analysis of Machining Thin-Wall Parts

2010 ◽  
Vol 458 ◽  
pp. 283-288 ◽  
Author(s):  
R. Izamshah R.A. ◽  
John Mo ◽  
Song Lin Ding
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
End Milling ◽  
Operating Cost ◽  
Weight Ratio ◽  
Milling Process ◽  
Machining Process ◽  
Thin Wall ◽  
Structural Components ◽  
Element Analysis

In an attempt to decrease weight, new commercial and military aircraft are designs with unitised monolithic metal structural components which contains of thinner ribs (i.e., walls) and webs (i.e., floors). Most of the unitised monolithic metal structural components are machined from solid plate or forgings with the start-to-finish weight ratio of 20:1. The resulting thin-walled structure often suffers a deformation which causes a dimensional surface error due to the action of the cutting force generated during the machining process. To alleviate the resulting surface errors, current practices rely on machining through repetitive feeding several times and manual calibration which resulting in long cycle times, low productivity and high operating cost. A finite element analysis (FEA) machining model is developed in this project to specifically predict the distortion or deflection of the part during end milling process. The model aims to provide an input for downstream decision making on error compensation strategy when machining a thin-wall unitised monolithic metal structural components. A set of machining tests have been done in order to validate the accuracy of the model and the results between simulation and experiment are found in a good agreement.

Optimization of Process Parameters for Cutting Force for Aluminium 7010 in CNC End Milling Process

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
M. Kishanth ◽  
P. Rajkamal ◽  
D. Karthikeyan ◽  
K. Anand
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Optimization Of Process Parameters ◽  
Cnc End Milling ◽  
End Milling Process

In this paper CNC end milling process have been optimized in cutting force and surface roughness based on the three process parameters (i.e.) speed, feed rate and depth of cut. Since the end milling process is used for abrading the wear caused is very high, in order to reduce the wear caused by high cutting force and to decrease the surface roughness, the optimization is much needed for this process. Especially for materials like aluminium 7010, this kind of study is important for further improvement in machining process and also it will improve the stability of the machine.

Modeling & Analysis of End Milling Process Parameters Using Artificial Neural Networks

2014 ◽  
Vol 592-594 ◽  
pp. 2733-2737 ◽  
Author(s):  
G. Harinath Gowd ◽  
K. Divya Theja ◽  
Peyyala Rayudu ◽  
M. Venugopal Goud ◽  
M .Subba Roa
Keyword(s):  
Neural Networks ◽  
Artificial Neural Networks ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Artificial Neural ◽  
End Milling Process

For modeling and optimizing the process parameters of manufacturing problems in the present days, numerical and Artificial Neural Networks (ANN) methods are widely using. In manufacturing environments, main focus is given to the finding of Optimum machining parameters. Therefore the present research is aimed at finding the optimal process parameters for End milling process. The End milling process is a widely used machining process because it is used for the rough and finish machining of many features such as slots, pockets, peripheries and faces of components. The present work involves the estimation of optimal values of the process variables like, speed, feed and depth of cut, whereas the metal removal rate (MRR) and tool wear resistance were taken as the output .Experimental design is planned using DOE. Optimum machining parameters for End milling process were found out using ANN and compared to the experimental results. The obtained results provβed the ability of ANN method for End milling process modeling and optimization.

Chatter Investigation in Titanium Milling

2014 ◽  
Vol 1019 ◽  
pp. 318-324
Author(s):  
Jean Claude Fwamba ◽  
Lerato Crescelda Tshabalala ◽  
Cebo Philani Ntuli ◽  
Isaac Tlhabadira
Keyword(s):  
Feed Rate ◽  
End Milling ◽  
Processing Condition ◽  
Weight Ratio ◽  
Dimensional Accuracy ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Chatter Vibrations

<span><p align="LEFT"><span><span style="font-family: Times New Roman;" face="Times New Roman">Titanium and its alloys have been experiencing extensive development over the past few decades. They have found wide applications in the aerospace, biomedical and automotive industries owing to their good strength-to-weight ratio and high corrosion resistance. Machining performance is often limited by chatter vibrations at the tool-workpiece interface. Chatter is an abnormal tool behaviour which is one of the most critical problems in the machining process and must be avoided to improve the dimensional accuracy and surface quality of the finished product. This research aims at investigating chatter trends in the end milling process and to identify machine parameters that have effects on chatter during machining. The machine parameters investigated include axial feed rate, spindle revolute speed and depth of cut. In this research, experimental data was collected using sensors to analyze the existence of chatter vibrations on each processing condition. This research showed that the combination of the machine parameters, feed rate and spindle speed within certain proportions has an influence on machine vibrations during end milling and if not managed properly, may lead to chatter. </span></span></p> <p align="LEFT"></p>

Residual Stresses Modelling of End Milling Process Using Numerical and Experimental Methods

2020 ◽  
Vol 978 ◽  
pp. 106-113
Author(s):  
Marimuthu K. Prakash ◽  
Kumar C.S. Chethan ◽  
Prasada H.P. Thirtha
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
End Milling ◽  
Orthogonal Cutting ◽  
Milling Process ◽  
Parent Material ◽  
Machining Processes ◽  
Element Analysis ◽  
1045 Steel ◽  
Cutting Model

Machining has been one of the most sort of process for realizing different products. It has significant role in the value additions process. Machining is one of the production process where material is removed from the parent material to realize the final part or component. Among machining, the well known machining processes are turning, milling, shaping, grinding and non-conventional machining processes like electric discharge machining, ultrasonic machining, chemical machining etc. The fundamental of all these processes being material removal in the form of chips using a tool either in contact or not in contact. In the present work, milling is being taken for study Finite element analysis is being used as a tool to understand the different phenomenon that underlies the machining processes. Of late, the machining induced residual stresses is of great interest to the researchers since the residual stresses have an impact on the functional performances. The present work is to model the milling process to predict the forces and residual stresses using finite element method. Unlike many researchers, the authors have attempted to develop oblique cutting model rather than an orthogonal cutting model. The present work was carried out on AISI 1045 steel.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

scholarly journals Non-Invasive Estimation of Machining Parameters during End-Milling Operations Based on Acoustic Emission

Sensors ◽  
2020 ◽  
Vol 20 (18) ◽  
pp. 5326
Author(s):  
Andrés Sio-Sever ◽  
Erardo Leal-Muñoz ◽  
Juan Manuel Lopez-Navarro ◽  
Ricardo Alzugaray-Franz ◽  
Antonio Vizan-Idoipe ◽  
...  
Keyword(s):  
Acoustic Emission ◽  
End Milling ◽  
Low Cost ◽  
Milling Process ◽  
Machining Process ◽  
Measuring System ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Processes ◽  
Non Invasive

This work presents a non-invasive and low-cost alternative to traditional methods for measuring the performance of machining processes directly on existing machine tools. A prototype measuring system has been developed based on non-contact microphones, a custom designed signal conditioning board and signal processing techniques that take advantage of the underlying physics of the machining process. Experiments have been conducted to estimate the depth of cut during end-milling process by means of the measurement of the acoustic emission energy generated during operation. Moreover, the predicted values have been compared with well established methods based on cutting forces measured by dynamometers.

A Finite Element Analysis for the Characteristics of Cutting Parameters in 3D Oblique Milling Process

2010 ◽  
Vol 97-101 ◽  
pp. 3010-3013
Author(s):  
Guo Hua Qin ◽  
S.Q. Xin ◽  
Dong Lu ◽  
Yi Ming Rong
Keyword(s):  
Finite Element ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Element Model ◽  
Milling Process ◽  
Machining Process ◽  
Element Analysis ◽  
Complete Procedure ◽  
Commercial Software Package ◽  
Chip Removal

In the field of aeronautical and astronautical manufacturing, milling is a basic machining process by which a surface is generated by progressive chip removal. Therefore, this paper reports a complete procedure of the finite element model for the 3D oblique milling process using the commercial software package ABAQUS. Effect of various parameters on cutting forces is mainly discussed. The model correctly exhibits the observed transition from small to large force with increasing cutting speed and cutting depth.

scholarly journals Finite Element Method of Nickel Chromium and Nickel Vanadium for Alternative CNC Machine Tool

2019 ◽  
Vol 9 (1) ◽  
pp. 4730-4733
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Tool Material ◽  
High Speed Steel ◽  
Life Time ◽  
Machining Process ◽  
Depth Of Cut ◽  
Cnc Machine ◽  
Element Analysis ◽  
Nickel Chromium

CNC tool is generally made of high speed steel (HSS) which has shorter life due to the increasing depth of cut. The steel shank wears within a short life time by the chips produced during machining process. And even the tool material cannot withstand a large amount of load. The damaged tool material is analysed and an alternate material is used to manufacture the tool. Alternate material used to manufacture the CNC tool which would have properties superior than HSS. The objective of this paper is to analyze the temperature increase & the thermal deformation of different materials like nickel-chromium and nickel-vanadium using Finite Element Analysis.

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