An Indirect Method for the Measurement of Micro-Milling Forces

2019 ◽  
Author(s):  
Xiaohong Lu ◽  
Furui Wang ◽  
Kun Yang ◽  
Yixuan Feng ◽  
Steven Y. Liang
Keyword(s):  
Measurement System ◽  
Indirect Method ◽  
Low Cost ◽  
Indirect Measurement ◽  
Transmission System ◽  
Micro Milling ◽  
Force Sensors ◽  
Milling Machine ◽  
Milling Force ◽  
Milling Forces

Abstract Nowadays, the measurement of micro-milling forces is mainly achieved by a force transducer. However, the frequency of force signal is high, due to the spindle super-speed, which leads to failure of the micro-milling forces measurement by using common force sensors. Additionally, micro force sensors with high-resolution and high sampling frequency are preferred, but they are often expensive. To determine the average micro-milling force with low cost and high precision, we propose an indirect method, by determining the power of the main transmission system of a micro-milling machine. First, the measurement system for the micro-milling machine tool power was introduced, and various sensors were used to measure the current and voltage respectively. Then, a high-frequency sampling system based on the Labview was developed to process the current and voltage signals, and to obtain the power data of the main transmission system. Through this process, the indirect measurement of micro-milling forces was achieved. Finally, we validated the effectiveness of the developed on-line measurement system and the proposed indirect measurement method for average micro-milling force by using experiments. The proposed method is practical and low-cost, and it can lay the foundation for further research on cutting energy consumption.

scholarly journals Low Cost Micro Milling Machine for Prototyping Plastic Microfluidic Devices

Proceedings ◽  
2018 ◽  
Vol 2 (13) ◽  
pp. 707 ◽  
Author(s):  
Md Mubarak Hossain ◽  
Tanzilur Rahman
Keyword(s):  
Developing Countries ◽  
Microfluidic Device ◽  
Low Cost ◽  
Microfluidic Devices ◽  
Micro Milling ◽  
Biological Research ◽  
Milling Machine ◽  
Plastic Materials ◽  
Milling Machines

Micro-milling is one of the commonly used methods of fabrication of microfluidic devices necessary for cell biological research and application. Commercial micro-milling machines are expensive, and researchers in developing countries can’t afford them. Here, we report the design and the development of a low-cost (<130 USD) micro milling machine and asses the prototyping capabilities of microfeatures in plastic materials. We demonstrate that the developed machine can be used in fabricating the plastic based microfluidic device.

Coupled thermal and mechanical analyses of micro-milling Inconel 718

2018 ◽  
Vol 233 (4) ◽  
pp. 1112-1126 ◽  
Author(s):  
Xiaohong Lu ◽  
Hua Wang ◽  
Zhenyuan Jia ◽  
Yixuan Feng ◽  
Steven Y Liang
Keyword(s):  
Inconel 718 ◽  
Cutting Temperature ◽  
Milling Process ◽  
Micro Milling ◽  
Force Model ◽  
Temperature Model ◽  
Milling Force ◽  
Mechanical Coupling ◽  
Milling Forces ◽  
Milling Force Model

Micro-milling forces, cutting temperature, and thermal–mechanical coupling are the key research topics about the mechanism of micro-milling nickel-based superalloy Inconel 718. Most current analyses of thermal–mechanical coupling in micro-milling are based on finite element or experimental methods. The simulation is not conducive to revealing the micro-milling mechanism, while the results of experiments are only valid for certain machine tool and workpiece material. Few analytical coupling models of cutting force and cutting temperature during micro-milling process have been proposed. Therefore, the authors studied coupled thermal–mechanical analyses of micro-milling Inconel 718 and presented a revised three-dimensional analytical model of micro-milling forces, which considers the effects of the cutting temperature and the ploughing force caused by the arc of cutting edge during shear-dominant cutting process. Then, an analytical cutting temperature model based on Fourier’s law is presented by regarding the contact area as a moving finite-length heat source. Coupling calculation between micro-milling force model and temperature model through an iterative process is conducted. The novelty is including cutting temperature into micro-milling force model, which simulates the interaction between cutting force and cutting temperature during micro-milling process. The established model predicts both micro-milling force and temperature. Finally, experiments are conducted to verify the accuracy of the proposed analytical method. Based on the coupled thermal–mechanical analyses and experimental results, the authors reveal the effects of cutting parameters on micro-milling forces and temperature.

scholarly journals Determination of Contact Potential Difference by the Kelvin Probe (Part II) 2. Measurement System by Involving the Composite Bucking Voltage

2016 ◽  
Vol 53 (6) ◽  
pp. 57-66 ◽  
Author(s):  
O. Vilitis ◽  
M. Rutkis ◽  
J. Busenbergs ◽  
D. Merkulovs
Keyword(s):  
Measurement System ◽  
Low Cost ◽  
Contact Potential Difference ◽  
Indirect Measurement ◽  
Potential Difference ◽  
Variable Component ◽  
Kelvin Probe ◽  
Contact Potential ◽  
Electronic Work Function

Abstract The present research is devoted to creation of a new low-cost miniaturised measurement system for determination of potential difference in real time and with high measurement resolution. Furthermore, using the electrode of the reference probe, Kelvin method leads to both an indirect measurement of electronic work function or contact potential of the sample and measurement of a surface potential for insulator type samples. The bucking voltage in this system is composite and comprises a periodically variable component. The necessary steps for development of signal processing and tracking are described in detail.

Aerodynamic Torque of a Butterfly Valve—Influence of an Elbow on the Time-Mean and Instantaneous Aerodynamic Torque

2000 ◽  
Vol 122 (2) ◽  
pp. 337-344 ◽  
Author(s):  
F. Danbon ◽  
C. Solliec
Keyword(s):  
Indirect Method ◽  
Low Cost ◽  
Indirect Measurement ◽  
Butterfly Valve ◽  
Hot Wire ◽  
Straight Pipe ◽  
Fluid Forces ◽  
Large Size ◽  
Shaft Torque ◽  
Aerodynamic Torque

Many technological devices use butterfly valves to control the flow of the process or as safety unit. The principal advantages of this type of valve are their simplicity, their low cost, their speed of closing and the weak pressure drop which they produce when they are completely open. For installations of large size, the actuator of the valve can be very expensive; thus it is essential to know well the fluid forces and the resulting torque exerted on the valve. Consequently, the variation of the shaft torque of the butterfly valves according to the opening is of great interest to calculate the power of the actuator. Initially the flow around the valve is characterized by means of hot wire anemometry. It is noted that the disturbances induced by the elbow and/or the valve are felt until a distance from approximately 8 times the pipe diameter. A method of direct measurement by torquemeter and an indirect method by integration of the pressure forces on the faces of the valve give access to the time-mean and instantaneous torque on the valve shaft. Comparisons between the direct and indirect measurement of the torque are made before engaging the analysis of the results. Close to the full opening, the torque presents fluctuations harmful to suitable lifespan of the valve. Compared to the straight pipe case, the temporal and spectral analyses of the instantaneous torque prove that the elbow induces important fluctuations when the valve is completely open. Several tests carried out according to the valve/elbow spacing show that these effects disappear beyond a distance from 8 to 10 times the diameter of the pipe. [S0098-2202(00)02902-3]

scholarly journals Nickel-Based Alloy Dry Milling Process Induced Material Softening Effect

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3758 ◽  
Author(s):  
Jun Zha ◽  
Zelong Yuan ◽  
Hangcheng Zhang ◽  
Yipeng Li ◽  
Yaolong Chen
Keyword(s):  
High Speed ◽  
Softening Temperature ◽  
Milling Process ◽  
Dry Milling ◽  
Milling Force ◽  
Softening Effect ◽  
Milling Temperature ◽  
Nickel Based Alloy ◽  
Alloy Softening ◽  
Milling Forces

Improving the cutting efficiency is the major factor for improving the processing of nickel-based alloys. The novelty of this research is the calibrated SiAlON ceramic tool dry milling nickel-based alloy process. Firstly, the nickel-based alloy dry milling process was analyzed through the finite element method, and the required milling force and temperature were deduced. Then, several dry milling experiments were conducted with the milling temperature, and the milling force was monitored. The change in cutting speeds was from 400 m/min to 700 m/min. Experimental results verified the reduction of the dry milling force hypothesized by the simulation. The experiment also indicated that with a cut depth of 0.3 mm, cut width of 6 mm, and feed per tooth of 0.03 mm/z, when milling speed exceeded 527.52 m/min, the milling force began to decrease, and the milling temperature exceeded the nickel-based alloy softening temperature. This indicated that easy cutting could be realized under high-speed dry milling conditions. The interpolation curve about average temperature and average milling forces showed similarity to the tensile strength reduction with the rise of temperature.

Experimental Analysis of Process Parameters to Manufacture Micro-Cavities by Micro-Milling

2012 ◽  
Vol 498 ◽  
pp. 91-96 ◽  
Author(s):  
J. Gomar ◽  
A. Amaro ◽  
E. Vázquez ◽  
J. Ciurana ◽  
C. Rodríguez
Keyword(s):  
Automotive Industry ◽  
Micro Milling ◽  
Geometric Features ◽  
Milling Machine ◽  
Machining Processes ◽  
New Approach ◽  
Biomedical Field ◽  
Dimensional Errors ◽  
Conventional Machining ◽  
Potential Opportunity

The use of conventional machining processes has been subject to important decline probably due to the increment in the use of emerging technologies. Therefore, the main applications of these traditional processes, such as automotive industry, are in crisis. In order to have a chance to compete successfully in the new trends, the machining industry must meet the needs of alternative sectors such as biomedical field. The aim of this study is to prove the capacity of micro-milling, by machining complex micro-cavities on aluminum workpiece using a conventional milling machine. Results are obtained by evaluating accuracy and geometric features. This study finds that the feed per tooth is a significant factor in order to obtain better results. The use of coolant increases the tool wear and therefore dimensional errors. This scope is a potential opportunity to reutilize the conventional machines from a new approach.

scholarly journals High-Resolution Atmospheric Sensing of Multiple Atmospheric Variables Using the DataHawk Small Airborne Measurement System

2013 ◽  
Vol 30 (10) ◽  
pp. 2352-2366 ◽  
Author(s):  
Dale A. Lawrence ◽  
Ben B. Balsley
Keyword(s):  
High Resolution ◽  
Measurement System ◽  
Current System ◽  
Low Cost ◽  
Structure Constant ◽  
Turbulence Structure ◽  
Quality Of Data ◽  
Airborne Measurement ◽  
Atmospheric Measurement ◽  
Atmospheric Variables

Abstract The DataHawk small airborne measurement system provides in situ atmospheric measurement capabilities for documenting scales as small as 1 m and can access reasonably large volumes in and above the atmospheric boundary layer at low cost. The design of the DataHawk system is described, beginning with the atmospheric measurement requirements, and articulating five key challenges that any practical measurement system must overcome. The resulting characteristics of the airborne and ground support components of the DataHawk system are outlined, along with its deployment, operating, and recovery modes. Typical results are presented to illustrate the types and quality of data provided by the current system, as well as the need for more of these finescale measurements. Particular focus is given to the DataHawk's ability to make very-high-resolution measurements of a variety of atmospheric variables simultaneously, with emphasis given to the measurement of two important finescale turbulence parameters, (the temperature turbulence structure constant) and ɛ (the turbulent energy dissipation rate). Future sensing possibilities and limitations using this approach are also discussed.

The Role of Cutter Eccentricity on Surface Finish and Milling Forces

2004 ◽  
Author(s):  
Tony L. Schmitz ◽  
Jeremiah Couey ◽  
Eric Marsh ◽  
Michael F. Tummond
Keyword(s):  
Surface Finish ◽  
Milling Machine ◽  
Time Domain Simulation ◽  
Machined Surface ◽  
Premature Failure ◽  
Series Of Experiments ◽  
Error Motion ◽  
Milling Forces ◽  
Chip Load

In this paper, the role of milling cutter eccentricity, commonly referred to as runout, is explored to determine its effects on surface topography and milling forces. This work is motivated by the observation that commercially-available cutter bodies often exhibit variation in the teeth/insert radial locations as a result of manufacturing issues. Consequently, the chip load on individual cutting teeth varies periodically, which can lead to premature failure of the cutting edges. Additionally, this chip load variation increases the roughness of machined surfaces. This research isolates the effect of runout on cutting forces and the machined surface finish in a series of experiments completed on a precision milling machine with 0.1 μm positioning repeatability and 0.02 μm spindle error motion. The runout is varied in a controlled fashion and results compared between experiment and a comprehensive time-domain simulation.

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