scholarly journals Effect of the dynamic stiffness of a five-axis machine tool on the quality of sculptured surface

2016 ◽  
Vol 8 (12) ◽  
pp. 168781401668330
Author(s):  
Wei Wang ◽  
Qingzhao Li ◽  
Yunfeng Jiang
Keyword(s):  
Surface Quality ◽  
Vibration Frequency ◽  
Dynamic Stiffness ◽  
Milling Process ◽  
Sculptured Surface ◽  
High Quality ◽  
Machine Center ◽  
Five Axis ◽  
Cutting Behavior

To achieve high quality of sculptured surface, a five-axis machine center must have excellent dynamic behavior. This article gives a new way to characterize and present the performance of machine center on milling sculptured surface which is constrained by the dynamic stiffness. First, the formation mechanism of surface quality is explained in intermittent milling process. It is mainly affected by the vibration frequency of cutting behavior. Second, the concept of dynamic stiffness of machine center is proposed and calculated based on the movement of multi-axis. To elaborate such effect, the map of dynamic stiffness on a sculptured surface, S part is obtained. The change of stiffness causes the different vibration frequency and then leads to different surface quality. Finally, experiments are conducted on S part by microscope and the waviness measurement. The results demonstrate the proposed method is very close to the true one. Presenting, measuring, and controlling the surface quality are easy for the user to understand the challenging performance of the machine center on milling sculptured surface.

Experimental investigation of the influence of cutting parameters on surface quality and on the special characteristics of micro-milled surfaces of hardened steels

2021 ◽  
pp. 095440622110130
Author(s):  
Barnabás Zoltán Balázs ◽  
Márton Takács
Keyword(s):  
Surface Quality ◽  
Surface Profile ◽  
Cutting Parameters ◽  
Relevant Information ◽  
Milling Process ◽  
Micro Milling ◽  
Machined Surface ◽  
Analysis Of Dynamics ◽  
Five Axis ◽  
Coated Carbide

Micro-milling is one of the most essential technologies to produce micro components, but due to the size effect, it has many special characteristics and challenges. The process can be characterised by strong vibrations, relatively large run-out and tool deformation, which directly affects the quality of the machined surface. This paper deals with a detailed investigation of the influence of cutting parameters on surface roughness and on the special characteristics of micro-milled surfaces. Several systematic series of experiments were carried out and analysed in detail. A five-axis micromachining centre and a two fluted, coated carbide micro-milling tool with a diameter of 500 µm were used for the tests. The experiments were conducted on AISI H13 hot-work tool steel and Böhler M303 martensitic corrosion resistance steel with a hardness of 50 HRC in order to gain relevant information of machining characteristics of potential materials of micro-injection moulding tools. The effect of the cutting parameters on the surface quality and on the ratio of Rz/ Ra was investigated in a comprehensive cutting parameter range. ANOVA was used for the statistical evaluation. A novel method is presented, which allows a detailed analysis of the surface profile and repetitions, and identify the frequencies that create the characteristic profile of the surface. The procedure establishes a connection between the frequencies obtained during the analysis of dynamics (forces, vibrations) of the micro-milling process and the characterising repetitions and frequencies of the surface.

scholarly journals Effect of High Speed Milling Process Parameters on the Milling Force and Surface Topography of AM50A Magnesium Alloy

2018 ◽  
Vol 36 (1) ◽  
pp. 124-131
Author(s):  
Hongji Zhang ◽  
Yuanyuan Ge ◽  
Hong Tang ◽  
Yaoyao Shi ◽  
Zengsheng Li
Keyword(s):  
Magnesium Alloy ◽  
Surface Quality ◽  
High Speed ◽  
Milling Process ◽  
Spindle Speed ◽  
Feed Speed ◽  
Milling Force ◽  
High Speed Milling ◽  
Milling Parameters

Within the scope of high speed milling process parameters, analyzed and discussed the effects of spindle speed, feed rate, milling depth and milling width on milling forces in the process of high speed milling of AM50A magnesium alloy. At the same time, the influence of milling parameters on the surface roughness of AM50A magnesium alloy has been revealed by means of the measurement of surface roughness and surface micro topography. High speed milling experiments of AM50A magnesium alloy were carried out by factorial design. Form the analysis of experimental results, The milling parameters, which have significant influence on milling force in high speed milling of AM50A magnesium alloy, are milling depth, milling width and feed speed, and the nonlinear characteristics of milling force and milling parameters. The milling force decreases with the increase of spindle in the given mill parameters. For the effects of milling parameters on surface quality of the performance, in the milling depth and feeding speed under certain conditions with the spindle speed increases the surface quality of AM50A magnesium alloy becomes better with the feed speed increases the surface quality becomes poor. When the spindle speed is greater than 12000r/min, the milling depth is less than 0.2mm, and the feed speed is less than 400mm/min, the milling surface quality can be obtained easily.

The Investigation of a Micro-Component Machined on a Custom-built Miniature Machine Tool

2012 ◽  
Vol 59 (2) ◽  
Author(s):  
Syaimak Abdul Shukor
Keyword(s):  
Surface Quality ◽  
Milling Process ◽  
Micro Milling ◽  
Batch Size ◽  
Geometrical Accuracy ◽  
Custom Made ◽  
Micro Parts ◽  
Solid Carbide ◽  
Steel Aisi

Custom-built Miniature Machine Tools (MMTs) are now becoming more popular with the demand for reduced energy consumption and workshop floor when machining small/medium batch size micro-components. This paper investigates the capability of a custom-built 4-axis MMT through machining an “adapted standard‟ of micro-testpiece. The experiments have been carried out in two different materials: Carbon Steel (AISI 1040) and Titanium Alloyed (TiAl6V4) using solid carbide flat end mill cutters with 0.6mm diameter. From here, the surface quality and geometrical accuracy of the machined testpiece are evaluated and analysed. The investigation has shown that acceptable geometrical accuracies and surface quality of the machined micro-parts can be achieved using the in-house developed MMT. These results show that the use of the custom-made MMT does not hinder the micro-milling process to produce a good and satisfactory surface quality (Ra=0.04-0.07μm) and acceptable geometrical accuracy.

Machining a Micro-Scale Structure Using an in-House Developed Miniature Machine Tool

2011 ◽  
Vol 418-420 ◽  
pp. 1502-1506
Author(s):  
Abdul Shukor Syaimak
Keyword(s):  
Surface Quality ◽  
Machine Tools ◽  
Milling Process ◽  
Micro Milling ◽  
Batch Size ◽  
End Mill ◽  
Geometrical Accuracy ◽  
Custom Made ◽  
Solid Carbide

Custom-built Miniature Machine Tools (MMTs) are now becoming more popular with the demand for reduced energy consumption and workshop floor when machining small/medium batch size micro-components. This paper investigates the capability of a custom-built 4-axis MMT through machining a micro-component demonstrator. The experiments have been carried out in Titanium Alloyed (TiAL6V4) using 0.6mm solid carbide flat end mill cutters. From here, the surface quality and geometrical accuracy of the machined testpiece are evaluated and analysed. The investigation has shown that acceptable geometrical accuracies and surface quality of the machined micro-demonstrator can be achieved using the in-house developed MMT. These results show that the use of the custom-made MMT does not hinder the micro-milling process to produce a good and satisfactory surface quality and acceptable geometrical accuracy.

Optimization of Fine-Grained Concrete Composition in Order to Improve the Quality of Units’ Front Surface

2018 ◽  
Vol 284 ◽  
pp. 1052-1057 ◽  
Author(s):  
Margarita A. Goncharova ◽  
V.V. Simbaev ◽  
O.V. Karaseva
Keyword(s):  
Surface Quality ◽  
Laboratory Tests ◽  
Front Surface ◽  
Special Focus ◽  
Rheological Characteristics ◽  
Concrete Composition ◽  
High Quality ◽  
Quality Class ◽  
Fine Grained

In this article, the results of optimizing fine-grained concretes are given. Laboratory tests were conducted to obtain a high-quality front surface of products formed according to two different methods. Special focus was given to the rheological characteristics of concrete mixture which make the biggest impact on the front surface quality class of units produced from modified fine-grained concretes.

Influence of milling process parameters and significance of tools to improve the surface quality of GFRP composites

2021 ◽  
pp. 1-17
Author(s):  
I. S. N. V. R. Prasanth ◽  
D. V. Ravishankar ◽  
M. Manzoor Hussain ◽  
Chandra Mouli Badiganti
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Milling Process ◽  
Gfrp Composites

Study on Removal Mechanism and Surface Quality of High Volume Fraction SiCp/Al Composites Based on Meso-scale

2021 ◽  
Author(s):  
Po Jin ◽  
Qi Gao ◽  
Quanzhao Wang ◽  
Wenbo Li
Keyword(s):  
Particle Size ◽  
Surface Quality ◽  
Feed Rate ◽  
Volume Fraction ◽  
High Volume ◽  
Milling Process ◽  
Subsurface Damage ◽  
High Volume Fraction ◽  
Removal Mechanism

Abstract The milling process of SiCp/Al composites with high volume fraction and large particle size has been studied in this paper. The stress and strain distribution of SiC reinforced particles and the removal mechanism of the material are analysed. The effects of milling depth and feed per tooth on surface quality were analysed. The effect of feed per tooth on the thickness of subsurface damage layer is revealed. The results show that in the end milling process of high volume fraction SiCp/Al composites, the blade diameter is larger relative to the particle size, which leads to the main removal forms of particle size: extrusion crushing and rolling crushing. The surface defects of the machined workpiece mainly include cavity, crack and delamination caused by extrusion of aluminum matrix. The surface quality of the machined workpiece can be improved by increasing the milling depth appropriately. The increase of the feed rate of each tooth will lead to the increase of the surface defect of the machined workpiece and the deterioration of the surface quality. When the feed rate per tooth increases from 4 to 8 μm, the thickness of subsurface damage increases from 47.7 to 60.5 μm. It is found that the ratio between the minimum cutting thickness of SiCp/Al composites and the radius of the cutting edge should be less than or equal to 4%.

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