Optimization Method of Rotational Axis Motion in 5-Axis Controlled Machining to Keep Command Tool Feed Rate

2020 ◽  
Author(s):  
Takayuki Nakamura ◽  
Kohei Ichikawa ◽  
Masanobu Hasegawa ◽  
Jun'ichi Kaneko ◽  
Takeyuki Abe
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Machining Process ◽  
Rotational Axis ◽  
Feed Speed ◽  
Machining Processes ◽  
Machining Time ◽  
Machined Surface ◽  
Lead Angle ◽  
Tool Posture

Abstract In recent machining processes, 5-axis controlled machine tool is widely used for machining complicated workpiece shape with curved surface. In such process, to achieve high productivity, planning method of cutting conditions to satisfy both following the commanded tool feed rate in machining process and realization of good surface roughness are required. In conventional study, it is known that lead angle of tool posture against local machined surface influence the surface roughness. Then, common commercial CAM systems have already functioned to avoid interference and control the lead angle in each cutter location. However, in the generated cutter locations by the conventional algorithms, when the tool posture changes rapidly, there is a problem that actual feed rate does not reach the command value and machining time becomes longer than expected. In this paper, we propose the new tool posture correction algorithm. In the proposed method, first, the rotational axis that causes the feed speed rate decline is specified by preliminary experiments. And, the jerk value that is the threshold for the feed speed decline is investigated. After that, for the NC program, the command value of the target axis is modified within a range where interference of cutting tool does not occur, thereby preventing a decline in the actual feed rate. This paper describes an outline of the proposed modification method and the effect of the modification of the target axis positions on the lead angle and the actual feed rate.

Tool Posture Planning Method for Low Rigidity Workpiece Considering Elastic Deformation Caused by Cutting Force

2020 ◽  
Author(s):  
Jun'ichi Kaneko ◽  
Yuki Okuma ◽  
Shumpei Sugita ◽  
Takeyuki Abe
Keyword(s):  
Cutting Force ◽  
Elastic Deformation ◽  
Feed Rate ◽  
Machining Process ◽  
Machining Time ◽  
Machined Surface ◽  
Nc Program ◽  
Blade Shape ◽  
Tool Posture ◽  
The Moment

Abstract In machining process for a workpiece with low rigidity such as a blade shape, it is required to consider elastic deformation of the workpiece shape itself due to cutting force. Conventionally, reduction of the cutting force in machining process is achieved by optimization of feed rate value in NC program. On the other hand, since a decrease in the feed rate causes an increase in machining time. So, other optimization algorithm is required. In this paper, a new method to suppress the elastic deformation of the workpiece by changing tool posture in multi-axis controlled machining is proposed. The proposed method is intended for finish machining process for blade shape with a ball end mill. In the proposed method, first, the cutting force loaded on the workpiece surface in a certain posture candidate is predicted, and an instantaneous cutting force at the moment when the machining surface is generated is estimated by model-based computer simulation. Based on this results, the amount of elastic deformation on the machined surface is estimated by FEM. This process is repeated at each cutter location and tool posture candidate, and the new tool posture that can minimize machining error caused by the elastic deformation is determined at each cutter location.

scholarly journals EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

2017 ◽  
Vol 18 (1) ◽  
pp. 147-154
Author(s):  
Mohammad Yeakub Ali ◽  
Wan Norsyazila Jailani ◽  
Mohamed Rahman ◽  
Muhammad Hasibul Hasan ◽  
Asfana Banu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Microfluidic Channels ◽  
Machining Parameters ◽  
Machining Processes ◽  
Dry Cutting ◽  
Minimum Quantity

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

Empirical study on ultrasonic assisted turn-milling

2021 ◽  
pp. 095440892110087
Author(s):  
Saeid Amini ◽  
Mohammad Baraheni ◽  
Mohammad Khaki
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Feed Rate ◽  
Rotational Speed ◽  
Milling Process ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Turn Milling

Turn-milling process has been paid attention in order to be used in multi-task machining processes. Moreover, looking for new machining techniques aimed at reducing cutting force is of important. Reducing cutting force in machining processes has the benefits of extending tool life and improving surface quality. One of the new concepts for reducing the cutting force is applying ultrasonic vibration. In this paper, effects of ultrasonic vibration under different machining parameters in turn-milling process of Al-7075 alloy will be investigated. In this order, a special mechanism was designed to apply ultrasonic vibration during machining process. Ultrasonic vibration exertion on the tool reduced cutting force and surface roughness up to 75% and 35%, respectively. Also tool rotational speed increment induced cutting force and surface roughness increment. In addition, tool feed rate and workpiece rotational speed increment caused cutting force and surface roughness increment. Although, feed rate was more influential.

Surface Intergrity of Inconel 718 under MQL Condition

2010 ◽  
Vol 150-151 ◽  
pp. 1667-1672 ◽  
Author(s):  
Che Hassan Che Haron ◽  
Jaharah Abd Ghani ◽  
Mohd Shahir Kasim ◽  
T.K. Soon ◽  
Gusri Akhyar Ibrahim ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Machining Process ◽  
Graphical Form ◽  
Depth Of Cut ◽  
Optimum Process ◽  
Machined Surface ◽  
Coated Carbide

The purpose of this study is to investigate the effect of turning parameters on the surface integrity of Inconel 718. The turning parameters studied were cutting speed of 90, 120, 150 m/min, feed rate of 0.15, 0.25, 0.25mm/rev and depth of cut of 0.3, 0.4, 0.5 mm under minimum quantity lubricant (MQL) using coated carbide tool. surface response methodology (RSM) design of experiment using Box-Behnken approach has been employed consisting of various combination of turning parameters Surface roughness, surface topography, microstructure and the micro hardness of the machined surface were studied after the machining process. Feed rate was found to be the most significant parameter affecting the surface roughness. The optimum parameter was obtained with Ra equal to 0.243 µm at cutting speed of 150 m/min, feed rate of 0.25 mm/rev and depth of cut of 0.3mm. A mathematical model for surface roughness was developed using Response Surface Methodology. The effect of turning parameters and factor interactions on surface roughness is presented in 3D graphical form, which helps in selecting the optimum process parameters to achieve the desired surface quality.

scholarly journals Effect on Material Removal Rate and Surface Finish in ECM Process When Machining Stainless Steel-316 with Cu Electrode

2019 ◽  
Vol 8 (4) ◽  
pp. 2933-2941
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Process Parameters ◽  
Surface Finish ◽  
Feed Rate ◽  
Electrolyte Concentration ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Machining Processes

Electrochemical Machining process is one of the popular non-traditional machining processes which is used to machine materials such as super alloys, Ti-alloys, stainless steel etc. Its working principle is based upon Faraday law of electrolysis. The aim of the present work is to optimize the ECM process parameters with the combination of SS 316 (job material) and Copper electrode (tool material). To explore the effect of ECM process parameters such as electrolyte concentration, voltage and current, feed rate on MRR and surface finish (Ra) of the job, total 27 experiments were conducted as per experimental scheme. The results of these experiments revealed that increase in electrolyte concentration decrease the mrr and surface roughness initially increases then decreases. Further, increase in current increases mrr initially and then decreases, surface roughness also increases. It is also noticed that increase in Feed rate mrr decreases and then increases, also surface roughness decreases then increases. Through RSM analysis it is found that the optimum conditions for maximum MRR, and minimum Surface roughness (Ra) is electrolyte concentration 150gm/lit, Voltage 13.5 V & feed 0.8 mm/min. The findings are discussed in the light of previous researches and subsequently conclusions are drawn.

scholarly journals Surface Roughness Values of Magnesium Alloy AZ31 When Turning by Using Rotary Cutting Tool

INSIST ◽  
2016 ◽  
Vol 1 (1) ◽  
pp. 54
Author(s):  
Gusri Akhyar ◽  
Suryadiwansa Harun ◽  
Arinal Hamni
Keyword(s):  
Surface Roughness ◽  
Magnesium Alloy ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Machined Surface ◽  
Rotary Cutting

Abstract - Magnesium and magnesium alloys is one of materials that worldwide used on automotive components due to very good  strength to weight ratio, resistant to corrosion, lighter compare to steel materials. Other than that magnesium has an advantage in easy to form and good machinability.  Nevertheless, magnesium known as metal which is easy to burned because of magnesium has low melting point. To maintain magnesium from burning quickly when proses machining, it needs to use coolant or lubricant to reduce temperature. Using of coolant when machining process can reduce temperature on cutting tool and work piece material, while using of lubricant can reduce friction between the cutting tool and work piece mateial. However, using of coolant and lubricant can harm for the environment and also coolant difficult to destroyed. Therefore, an alternative method to reduce the temperature when machining of magnesium alloy is using  the rotary cutting tool system. In the rotary cutting tool system, the cutting tool has a time to experience cooling in the period time. Other than aspect of temperature, surface roughness values are representative of surface of quality of produced componens. In this research, surface roughness value of magnesium alloy of AZ31 observed in ranges of work piece cutting speed of  (Vw) 25, 50, 120, 160, 200 m/min, rotary cutting speed of (Vt) 25, 50, 75 m/min, feed rate of (f) 0,05  and 0,10 mm/rev, and depth of cut of 0.2 mm. The turning process was done by using two kinds of diameter of rotary cutting tools are 16 and 20 mm, and without applying of coolant. The results of the research showed that the minimum surface roughness value of machined surface was 0,62𝝻m by using insert with diameter of 16 mm, while the maximum surface roughness value of machined surface was 2,86 𝝻m by using insert with diameter of 20 mm. This result stated that the increase in the diameter of rotary cutting tool gives a significant effect on the produced surface roughness value. Factor of feed rate also gives a significant contribution on the surface roughness value of machined magnesium surface.  The increase in feed rate generated significantly surface roughness value as long as the trials experiments. The produced surface roughness values inversely proportional to the cutting speed of rotary cutting tool.Keywords - magnesium, rotary tool, surface roughness, turning. 

Investigation on Precision Turning of Titanium Alloys

2012 ◽  
Vol 622-623 ◽  
pp. 399-403 ◽  
Author(s):  
Tarun Thomas George ◽  
J. Venugopal ◽  
M. Anthony Xavior ◽  
R. Vinayagamoorthy
Keyword(s):  
Surface Roughness ◽  
Titanium Alloys ◽  
Working Conditions ◽  
Cutting Temperature ◽  
Machining Process ◽  
Machining Processes ◽  
Machined Surface ◽  
Percentage Contribution ◽  
Precision Turning

The quality of a machined surface is becoming more and more important to satisfy the increasing demands of sophisticated component performance, longevity, and reliability. The objective of this paper is to analyze the performance of precision turning using conventional lathe on Ti6Al4V under dry working conditions. Various parameters that affect the machining processes were identified and a consensus was reached regarding its values. The proposed work is to perform machining under the selected levels of conditions and parameters and to estimate the, cutting temperature and surface roughness generated as the result of the machining process. ANOVA is used to find the percentage contribution of each parameter to the surface roughness and cutting temperature.

The effect of machining processes on the physical and surface characteristics of AA2024-B4C-SiC hybrid nanocomposites fabricated by hot pressing method

2021 ◽  
pp. 002199832199641
Author(s):  
Zihni Alp Çevik ◽  
Abdullah Hasan Karabacak ◽  
Metin Kök ◽  
Aykut Canakçı ◽  
S Suresh Kumar ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Removal Rate ◽  
Surface Characteristics ◽  
Hybrid Nanocomposites ◽  
Machining Process ◽  
Machining Processes ◽  
Machined Surface ◽  
Pressing Method ◽  
Weight Percentage ◽  
Sic Particles

In this study, an attempt was made on the AA2024 alloy based hybrid nanocomposites reinforced with different weight percentage of SiC and B4C particles to investigate their physical and machinability characteristics including surface morphology. The Material Removal Rate (MRR), Surface Roughness (SR) of the nanocomposites machined by various machining processes namely Abrasive Water Jet (AWJ) machining, Wire Electrical Discharge (WED) machining and Computer Numerical Controlled (CNC) turning processes were studied comparatively. The machined surface formed by the each machining process is examined and its surface quality was discussed for each hybrid nanocomposite. Results show that the hardness is increased to 101.6 BHN from 179.4 BHN, when 2 wt.% of B4C and SiC particles is added to AA2024 matrix. Observed from the results that the addition of 2 wt.% of B4C and SiC particles produces the highest porosity of 3.36% for nanocomposite samples. The experimental results revealed that the addition of particulates in to the matrix reduces the MRR and increases SR. MRR results showed that hybrid nanocomposites machined by AWJ technique has minimum MRR of 0.0221 mm3/min. The surface roughness of the nanocomposites machined with AWJ process was 3.2 µm and increased to 6.81 µm for the AA2024-B4C-SiC hybrid nanocomposites machined with CNC process.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

Sign in / Sign up

Export Citation Format

Share Document