scholarly journals Effect of the lead angle and the radius of curvature on the cutting forces in a 5-axis milling of sculptured surfaces

Mechanik ◽  
2018 ◽  
Vol 91 (1) ◽  
pp. 18-22
Author(s):  
Michał Gdula ◽  
Jan Burek
Keyword(s):  
Turbine Blade ◽  
Convex Surface ◽  
Experimental Studies ◽  
Surface Profile ◽  
Radius Of Curvature ◽  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
Inconel 718 Alloy ◽  
Machined Surface ◽  
Lead Angle

Experimental studies are presented, were conducted that aimed at determining the mathematical models of the influence of the lead angle and the radius of curvature of the profile of machined sculptured surface on the components of the cutting force. The object of the experimental studies was a convex and concave surface of a turbine blade of Inconel 718 alloy. The toroid cutter was used for the tests. Based on the results of the study it was found that the lead angle in the machining of the convex surface and concave turbine blade should be continuously varied with the change of radius of curvature in the direction of the machined surface profile.

scholarly journals Cutting layer and cutting forces in a 5-axis milling of sculptured surfaces using the toroidal cutter

2017 ◽  
Vol 4 (17) ◽  
pp. 98-122
Author(s):  
Michal GDULA ◽  
Jan BUREK
Keyword(s):  
Turbine Blade ◽  
Convex Surface ◽  
Experimental Studies ◽  
Surface Profile ◽  
Radius Of Curvature ◽  
Geometrical Parameters ◽  
Inconel 718 Alloy ◽  
Axis Orientation ◽  
Five Axis ◽  
Toroidal Cutter

The purpose of this article was to evaluate the significance of the influence of five- axis orientation parameters of a toroidal cutter axis and the geometrical parameters of the machined sculptured surface on the intersection of the cut layer in a 5-axis machining. An impact assessment was performed by simulating concave-convex and convex-concave surfaces using a discrete method of direct transformation in a CAD environment. It was shown that only the radius of curvature of the surface in the feed direction and the angle of the tool axis affected the change in the intersection of the cutting layer. Subsequently, experimental tests were conducted that aimed at determining the mathematical models of the influence of these important parameters on the components of the cutting force. The object of the experimental studies was a convex and concave surface of a turbine blade of Inconel 718 alloy. The R300-016B20L-08L Sandvik Coromant toroid cutter was used for the tests. Based on the results of the study it was found that the lead angle in the machining of the convex surface and concave turbine blade should be continuously varied with the change of radius of curvature in the direction of the machined surface profile

scholarly journals Method of controlling the lead angle of the toroidal cutter axis in 5-axis machining of the turbine blade

Mechanik ◽  
2017 ◽  
Vol 90 (8-9) ◽  
pp. 710-712 ◽  
Author(s):  
Michał Gdula ◽  
Jan Burek ◽  
Marcin Żółkoś
Keyword(s):  
Turbine Blade ◽  
Control Method ◽  
Classical Method ◽  
Surface Profile ◽  
Radius Of Curvature ◽  
Sculptured Surface ◽  
Lead Angle ◽  
Toroidal Cutter

Presented is the own concept control method an lead angle axis of the toroidal cutter, depending on the radius of curvature of the machined sculptured surface profile. The method verified on the example machining of the turbine blade. In order to compare the effects of this method, to the classical method (without adaptation lead angle), tests were performed for both these methods.

Crater Geometry and Volume From Electro-Discharge Machined Surface Profiles by Data Dependent Systems

1980 ◽  
Vol 102 (4) ◽  
pp. 289-295 ◽  
Author(s):  
S. M. Pandit ◽  
K. P. Rajurkar
Keyword(s):  
Impulse Response Function ◽  
Surface Profile ◽  
Operating Conditions ◽  
Surface Generation ◽  
Radius Of Curvature ◽  
Regression Equations ◽  
Machining Time ◽  
Machined Surface ◽  
Depth Ratio ◽  
Single Discharge

This paper applies a recently developed methodology called Data Dependent Systems to model and analyse the process of Electro-Discharge Machined (EDM) surface generation. A first order stochastic differential equation is developed and physically interpreted from the EDM surface profile measurements under varying pulse duration and machining time. The impulse response function of this model is used to define a characteristic crater geometry. The depth and diameter to depth ratio of such a crater is determined and employed in deriving the radius of curvature and the volume. Experimental measurements are utilized to illustrate the development of regression equations and nomograms, useful in practice to obtain surfaces with desired geometry. It is shown that the depth diameter to depth ratio, and volume of the characteristic craters obtained from actual multiple discharge situation under operating conditions agree fairly well with the past single discharge physics investigations.

scholarly journals Empirical Models for Surface Roughness and Topography in 5-Axis Milling Based on Analysis of Lead Angle and Curvature Radius of Sculptured Surfaces

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 932
Author(s):  
Michał Gdula
Keyword(s):  
Surface Roughness ◽  
Inconel 718 ◽  
Curvature Radius ◽  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
Inconel 718 Alloy ◽  
Milling Cutter ◽  
Axis Orientation ◽  
Variable Curvature ◽  
Tool Axis

The orientation of the tool axis and the variable curvature of the machined profile of a sculptured surface have a significant impact on the roughness and topography of the surface in the process of 5-axis milling by means of a toroidal milling cutter. The selection of the orientation of the toroidal milling cutter axis relative to the radius of curvature of the machined surface profile is very important as it can provide a better surface quality and an even distribution of roughness parameters. In this paper, an attempt to carry out model tests to obtain mathematical relationships was made. These relationships were to determine the impact of the tool axis orientation and the variable curvature radius of the machined profile on the surface roughness and its topography in the 5-axis milling process of sculptured surfaces. The tests were conducted on an example of a turbine blade made of Inconel 718 alloy. A measurable effect of the work undertaken was the development of model relationships that can be applied in specialized modules of CAM (Computer Aided Manufacturing) systems supporting the programming of 5-axis machining of sculptured surfaces. The models developed will also make it possible to obtain an evenly distributed roughness on the machined sculptured surface, especially on the surface of the turbine blades of the Inconel 718 alloy, as indicated by the results of the tests carried out.

Five-axis milling of sculptured surfaces of the turbine blade

2018 ◽  
Vol 90 (1) ◽  
pp. 146-157 ◽  
Author(s):  
Michal Gdula ◽  
Jan Burek ◽  
Lukasz Zylka ◽  
Marcin Plodzien
Keyword(s):  
Turbine Blade ◽  
Turbine Blades ◽  
Dimensional Accuracy ◽  
Milling Process ◽  
Radius Of Curvature ◽  
Sculptured Surfaces ◽  
Axis Orientation ◽  
Content Type ◽  
Five Axes ◽  
Toroidal Cutter

Purpose The purpose of this paper is to determine the influence of a toroidal cutter axis orientation and a variable radius of curvature of the machined contour of sculptured surface on the five-axes milling process. Simulation and experimental research performed in this work are aimed to determine the relationship between the parameters of five-axes milling process and the shape and dimensional accuracy of curved outline of Inconel 718 alloy workpiece. Design/methodology/approach A subject of research are sculptured surfaces of the turbine blade. Simulation research was performed using the method of direct mapping tools in the CAD environment. The machining research was carried out with the use of multi-axis machining center DMU 100 monoBLOCK DMG, equipped with rotating dynamometer to measure the components of the cutting force. To control the shape and dimensional accuracy, the coordinate measuring machine ZEISS ACCURA II was used. Findings In this paper, the effect of the toroidal cutter axis orientation and the variable radius of curvature of the machined contour on the parameters of five-axes milling process and the accuracy of the sculptured surfaces was determined. Practical implications Five-axes milling with the use of a toroidal cutter is found in the aviation industry, where sculptured surfaces of the turbine blades are machined. The results of the research allow more precise planning of five-axes milling and increase of the turbine blades accuracy. Originality/value This paper significantly complements the current state of knowledge in the field of five-axes milling of turbine blades in terms of their accuracy.

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.

Automatic Planning for 5-Axis Sculptured Surface Machining

1994 ◽  
Author(s):  
Yuan-Shin Lee ◽  
Tien-Chien Chang
Keyword(s):  
Sculptured Surface ◽  
Sculptured Surfaces ◽  
Design Modification ◽  
Surface Machining ◽  
Sculptured Surface Machining ◽  
Cutter Path ◽  
Automatic Planning ◽  
Five Axis ◽  
Five Axes ◽  
Complete Operation

Abstract In modern product design, sculptured surfaces are commonly used for functional and artistic shape design. Design of sculptured surfaces is evolutionary, consisting primarily of incremental changes to existing part surfaces. Manual operation planning for sculptured surface machining is known to be error-prone and inefficient, which requires considerable checking, verification, and rework. Five-axis machining has higher productivity and better machining quality than 3-axis machining. However, the programming for 5-axis machining is more difficult due to the complex simultaneous cutter movements along the machine’s five axes. This paper presents a systematic methodology to generate operation plans for 5-axis sculptured surface machining. A complete operation plan and the error-free cutter path can be automatically generated from the CAD part design. To achieve design for manufacturing of sculptured surface products, the machining unfeasibility information can be fed back to the designer for further design modification. Results of computer implementation and testing examples are also presented.

Experimental and Numerical Modal Analysis of Composite Laminated Shells

2019 ◽  
Vol 161 (A1) ◽  
Keyword(s):  
Heat Dissipation ◽  
Mass Matrix ◽  
Experimental Studies ◽  
Free Vibration Analysis ◽  
Mode Shapes ◽  
Radius Of Curvature ◽  
Lumped Mass ◽  
Auxiliary Equipment ◽  
Mass Model ◽  
Laminated Shells

The presence of cut outs at different positions of laminated shell component in marine and aeronautical structures facilitate heat dissipation, undertaking maintenance, fitting auxiliary equipment, access ports for mechanical and electrical systems, damage inspection and also influences the dynamic behaviour of the structures. The aim of the present study is to establish a comprehensive perspective of dynamic behavior of laminated deep shells (length to radius of curvature ratio less than one) with cut-out by experiments and numerical simulation. The glass epoxy laminated composite shell has been prepared in the laboratory by resin infusion. The experimental free vibration analysis is carried out on laminated shells with and without cut-out. The mass matrix is developed by considering rotary inertia in a lumped mass model in the numerical modeling. The results obtained from numerical and experimental studies are compared for verification and the consistency between mode shapes is established by applying modal assurance criteria.

scholarly journals Technological Features in Processing of Conical Lenses

2020 ◽  
Vol 19 (6) ◽  
pp. 521-527
Author(s):  
M. I. Filonova ◽  
R. O. Dias Gonzalez ◽  
A. A. Sukhotzkiy ◽  
A. S. Kozeruk ◽  
A. V. Semchuonok
Keyword(s):  
Glass Plate ◽  
Experimental Studies ◽  
Central Zone ◽  
Conical Surface ◽  
Work Piece ◽  
Cylindrical Shape ◽  
Cylindrical Blank ◽  
Machined Surface ◽  
Optimal Sequence ◽  
Plane Parallel

The paper presents the technology of obtaining flat-conical lenses (axicons) by the method of free grinding a work-piece to a flat tool through a layer of abrasive suspension. For this, theoretical and experimental studies of the regularities of stock removal from the base of the cone and its lateral surface have been carried out. The processing modes have been identified that ensure both uniform operation of the flat surface of  the part and enhanced removal of  the allowance in the edge or central zone of this surface. During the study of the processing of the conical surface, the set-up parameters of the technological equipment have been established, at which there is a minimum deviation of the generatrix of the cone from straightness and maximum productivity of the process. The stages of processing conical lenses are proposed, which allow to assign the optimal sequence of operations in the manufacture of this type of parts from blanks of a cylindrical shape in cases where  the ratio of the height of the cone to the diameter of its base H/d £ 0.5. The main stages of processing include: grinding of the bases of cylindrical blanks with maintaining their mutual parallelism with a given accuracy; polishing one of the cylinder bases to achieve the required roughness and deviation from non-flatness; fastening a cylindrical blank to an auxiliary plane-parallel glass plate using molecular cohesion forces; mechanical fastening of a cylindrical work-piece with a collet adapter mandrel for a plane-parallel glass plate; applying the nearest sphere to the second base of the cylindrical blank; drawing a conical surface on the spherical part of a plano-convex lens; grinding and polishing the conical surface to achieve the required roughness  and straightness of the cone generatrix. The degree of efficiency of the setup parameters of the machine has been revealed depending on the technological heredity of the work-piece from the point of view of the distribution of the allowance to be removed over the machined surface. 

scholarly journals Simultaneous Measurement of BRDF and Surface Curvature by using Pattern Illumination

2020 ◽  
Vol 2020 (28) ◽  
pp. 356-360
Author(s):  
Shinichi Inoue ◽  
Norimichi Tsumura
Keyword(s):  
Simultaneous Measurement ◽  
Convex Surface ◽  
Incident Light ◽  
Radius Of Curvature ◽  
Measurement Apparatus ◽  
Planar Surfaces ◽  
Angle Of Reflection ◽  
Bidirectional Reflection Distribution Function ◽  
Bidirectional Reflection ◽  
Normal Angle

In this study, we propose the simultaneous measurement method of the bidirectional reflection distribution function (BRDF) and the radius of curvature by using pattern illumination. For nonplanar objects, the angle of reflection light changes according to the surface normal angle of curved object. Therefore, it is necessary to consider the effects of curved surfaces when measuring the BRDF on non-planar surfaces. We suppose a convex surface that can be represented by a constant radius of curvature. The pattern of illumination was generated by placing the illumination mask with pattern apertures in the incident light path of the BRDF measurement apparatus in which the incident light is collimated light. We developed the measurement apparatus. We measured four types of sample with different BRDFs on three different radiuses of curvature. The results showed that the BRDF and the radius of curvature can be measured simultaneously by using the pattern illumination.

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