Dynamic modeling and experimental investigation of hole making accuracy in the helical milling process

2021 ◽  
pp. 095440892110576
Author(s):  
Omid Paysarvi ◽  
Mohammad Mahdi Abootorabi ◽  
Mohammad Mahdi Jalili
Keyword(s):  
Rotational Speed ◽  
Cutting Tool ◽  
Tool Material ◽  
Experimental Tests ◽  
Milling Process ◽  
Helical Milling ◽  
The Novel ◽  
Hole Making ◽  
Tool Diameter ◽  
Chip Removal

Helical milling is one of the novel hole-making methods to create a hole with high accuracy and quality. In this study, the helical milling process is dynamically modeled using a set of second-order differential equations. In this modeling, the tool is considered a cantilever beam with a degree of freedom in all three directions of x, y, and z. Experimental tests were conducted to investigate the validity of the obtained theoretical relations and the effects of different parameters such as material, diameter, and rotational speed of the cutting tool on the precision of the created hole. The error of the theoretical relations in predicting the hole diameter is 2.7%, indicating the high precision of the accomplished modeling. Theoretical relations show that the error of the chip removal path decreases by increasing each of the parameters, namely, tool stiffness, the rotational speed of the tool, tool diameter, and tangential feed per tooth. In contrast, the error of the chip removal path increases by increasing each of the parameters, namely, the speed of the tool in the helical path and axial feed per tooth. It has been shown that improving the cutting tool material in terms of strength or increasing the rotational speed of the tool and the cutting tool diameter causes a reduction in the diametrical error. It has been shown that the diametrical error rate is 0.9% with the change of the cutting tool from HSS-E to carbide, and it has reduced to 0.6% by increasing the rotational speed of the tool from 900 r/min to 2100 r/min.

Analytical Calculation of Cutter/Workpiece Engagements for Helical Hole Milling

2009 ◽  
Author(s):  
Jue Wang ◽  
Derek Yip-Hoi
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Analytical Calculation ◽  
Milling Process ◽  
Helical Milling ◽  
Helicoidal Surface ◽  
Swept Volume ◽  
Intersection Geometry ◽  
Intersection Curves ◽  
Solid Modeler

Helical milling is a 3-axis machining operation where a cutting tool is feed along a helix. This operation is used in ramp-in and ramp-out moves when the cutting tool first engages the workpiece, for contouring and for hole machining. It is increasingly finding application as a means for roughing large amounts of material during high speed machining. Simulating the helical milling process requires Cutter/Workpiece Engagement (CWE) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. For hole milling an additional complication comes from self-intersections that occur with the tool swept volume. This makes the generation of the instantaneous in-process workpiece needed for finding the CWE difficult. In this paper we present an analytical approach for finding the engagement geometry that utilizes the intersection curves between a cylinder representing a flat end mill and the helicoidal surface generated by the bottom of the tool as it feeds downwards along the helix. This technique can be integrated into a solid modeler based approach for machining simulation. It has the advantage of not require instantaneous updates of the workpiece as is typically the case in finding CWEs.

Geometric Modeling of Cutter/Workpiece Engagements for Helical Milling With Flat End Mills

2007 ◽  
Author(s):  
Eyyup Aras ◽  
Derek Yip-Hoi
Keyword(s):  
Geometric Modeling ◽  
High Speed ◽  
Tool Path ◽  
Cutting Tool ◽  
Milling Process ◽  
Helical Milling ◽  
Mapping Technique ◽  
Depth Of Cut ◽  
Modeling Methodology ◽  
End Mills

Helical milling is a 3-axis machining operation where a cutting tool is feed along a helix. This operation is used in ramp-in and ramp-out moves when the cutting tool first engages the workpiece, for contouring and for hole machining. It is increasingly finding application as a means for roughing large amounts of material during high speed machining. Modeling the helical milling process requires cutter/workpiece engagements (CWEs) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. In this paper we present a geometric modeling methodology for finding engagements during helical milling with flat end mills. A mapping technique has been developed that transforms a polyhedral model of the removal volume from Euclidean space to a parametric space defined by location along the tool path, engagement angle and the depth-of-cut. As a result, intersection operations are reduced to first order plane-plane intersections. This approach reduces the complexity of the cutter/workpiece intersections and also eliminates robustness problems found in standard polyhedral modeling and improves accuracy over the Z-buffer technique. The reported method has been implemented and tested using a combination of commercial applications. This paper highlights ongoing collaborative research into developing a Virtual Machining System.

Performance of Tools Design when Helical Milling on Carbon Fiber Reinforced Plastics (CFRP) Aluminum (Al) Stack

2013 ◽  
Vol 465-466 ◽  
pp. 1075-1079 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Z. Mohid ◽  
M.R. Hamzah ◽  
A.F. Yusuf ◽  
N.A. Rahman
Keyword(s):  
Milling Process ◽  
Helical Milling ◽  
Machining Parameters ◽  
Reinforced Plastics ◽  
Comparable Performance ◽  
Hole Making ◽  
Milling Characteristics ◽  
The Common ◽  
Fiber Reinforced Plastics

Hole making process is not strictly to the drilling technique where others machining could also influence to the quality in CFRP hole.Therefore, helical milling process becomes as an alternative method to produces bore on CFRP plate thus minimizing the defects. The common defects on CFRP are delamination, splintering and cracking. Meanwhile, if the CFRP stacking together with aluminum plate, burr at exit hole of aluminium plate is produced. Therefore, it is essential to control the critical machining parameters to assure a good quality of the hole. The main objective of this project is to improve the hole quality of CFRP/AL stack in terms of surface roughness using helical milling technique. In addition the cutting force and temperature will be measured as well. There are three levels of cutting speeds; two levels of feed rate and depth per helical path are made accordingly to helical milling characteristics. It was found that all tool design exhibit comparable performance for helical milling process on CFRP/Al stack.

Analysis of Cutting Forces in Helical Milling Process

2011 ◽  
Vol 215 ◽  
pp. 9-13 ◽  
Author(s):  
H.Y. Wang ◽  
Xu Da Qin ◽  
Qi Wang
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Rotational Speed ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Milling Process ◽  
Helical Milling ◽  
Depth Of Cut ◽  
Cutting Experiment ◽  
Tool Cutting

Helical milling is used to generate holes, in which a tool attached to the rotating spindle traverses a helical trajectory, and the diameter of holes will be larger than that of the tool. Based on the principle of helical milling, this paper establishes analytical model of cutting forces. As the cutter travels on the helical path, intersection between the tool and the workpiece changes continuously, in which chip thickness and direction of the cutting forces will vary simultaneously. The cutting forces are not only direct proportional to the axial depth of cut, but also related to the rotational speed and orbital speed of the tool. Cutting experiment is conducted for the titanium alloy. The result shows that the simulated cutting force can be used to predict the change of cutting force under different conditions.

Experimental Study of Helical Milling on CFRP (Carbon Fibre Reinforced Polymer) for the Hole Making Process

2012 ◽  
Vol 576 ◽  
pp. 68-71 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Zazuli Mohid ◽  
M.F.M. Jamil ◽  
K.C. Mat ◽  
R. Koyasu ◽  
...  
Keyword(s):  
Experimental Study ◽  
Milling Process ◽  
Tool Design ◽  
Fiber Reinforced Polymer ◽  
Helical Milling ◽  
Reinforced Polymer ◽  
Milling Operation ◽  
Carbon Fibre Reinforced Polymer ◽  
Hole Making ◽  
Fibre Reinforced Polymer

Generate borehole by helical milling process may be used effectively since accurate location of the hole may be secured by means of the feed screw graduations. Fiber delamination which is the main defect occurred during hole making process on carbon fiber reinforced polymer (CFRP) were investigate throughout an experimental study. Effects of thrust force (Fz), delamination factor (Fd) and surface roughness are evaluated. Objective of the experiment are to find best cutting parameter and tool design suitable to performed helical milling operation on CFRP. Two types of end mill with 4 flutes were used and results are evaluated. It was found that tool design 2-1 has higher performance on CFRP.

Lifetime predictions for a ceramic cutting tool material at high temperatures

1987 ◽  
Vol 22 (6) ◽  
pp. 2051-2057 ◽  
Author(s):  
B. Gurumoorthy ◽  
K. Kromp ◽  
F. B. Prinz ◽  
A. C. Bornhauser
Keyword(s):  
High Temperatures ◽  
Cutting Tool ◽  
Tool Material ◽  
Ceramic Cutting Tool

scholarly journals Shoulder Related Temperature Thresholds in FSSW of Aluminium Alloys

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4375
Author(s):  
David G. Andrade ◽  
Sree Sabari ◽  
Carlos Leitão ◽  
Dulce M. Rodrigues
Keyword(s):  
Heat Generation ◽  
Process Parameters ◽  
Rotational Speed ◽  
Aluminium Alloys ◽  
Spot Welding ◽  
Base Material ◽  
Main Process ◽  
Welding Temperature ◽  
Friction Stir ◽  
Tool Diameter

Friction Stir Spot Welding (FSSW) is assumed as an environment-friendly technique, suitable for the spot welding of several materials. Nevertheless, it is consensual that the temperature control during the process is not feasible, since the exact heat generation mechanisms are still unknown. In current work, the heat generation in FSSW of aluminium alloys, was assessed by producing bead-on-plate spot welds using pinless tools. Coated and uncoated tools, with varied diameters and rotational speeds, were tested. Heat treatable (AA2017, AA6082 and AA7075) and non-heat treatable (AA5083) aluminium alloys were welded to assess any possible influence of the base material properties on heat generation. A parametric analysis enabled to establish a relationship between the process parameters and the heat generation. It was found that for rotational speeds higher than 600 rpm, the main process parameter governing the heat generation is the tool diameter. For each tool diameter, a threshold in the welding temperature was identified, which is independent of the rotational speed and of the aluminium alloy being welded. It is demonstrated that, for aluminium alloys, the temperature in FSSW may be controlled using a suitable combination of rotational speed and tool dimensions. The temperature evolution with process parameters was modelled and the model predictions were found to fit satisfactorily the experimental results.

CAD AND CAE TECHNOLOGIES OF A NOVEL PLANE SIX-BAR SWAYING MACHINE

2008 ◽  
Vol 07 (01) ◽  
pp. 65-67
Author(s):  
CHANGPING ZOU ◽  
LI DU ◽  
XIANDE HUANG
Keyword(s):  
High Pressure ◽  
Kinetic Analysis ◽  
Rotational Speed ◽  
Preliminary Analysis ◽  
Unit Weight ◽  
The Novel ◽  
Parameterized Modeling ◽  
New Type ◽  
Working Principle ◽  
Key Dimensions

A new type of six-bar swaying machine was put forward, which is an ingenious combination of plane multi-bar mechanism and high pressure oil cylinder. Preliminary analysis shows that this machine has many advantages, such as the torque produced by its unit weight, its small size, its light deadweight, etc. Thus it can be applied to situations that need swaying mechanism with low rotational speed and great torque. Firstly, the mechanism composition and working principle of the swaying machine were introduced. Secondly, parameterized modeling of the mechanism was carried out by utilizing software ADAMS. Then kinematic analysis and kinetic analysis were completed by using ADAMS. Finally, key dimensions were adjusted according to kinetic analysis. These tasks are believed to be beneficial to the development of the novel transmission.

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