A Method for Using a Virtual Machining Simulation to Consider Both Equivalent CO2Emissions and Machining Costs in Determining Cutting Conditions

2015 ◽  
Vol 9 (2) ◽  
pp. 115-121 ◽  
Author(s):  
Hirohisa Narita ◽  
Keyword(s):  
Evaluation System ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Machining Process ◽  
Machining Simulation ◽  
End Mill ◽  
Virtual Machining ◽  
Mill Operation ◽  
Nc Program

An evaluation system for calculating equivalent CO2emissions and machining costs is developed using an activity-based model. The system can evaluate a machining process from an NC program, workpiece information, and cutting tool information, and it can then calculate accurate equivalent CO2emissions and the machining cost. The cutting speed of an end mill operation is evaluated in terms of the equivalent CO2emission and the machining cost. Based on the results, optimal cutting conditions are determined to minimize the equivalent CO2emissions and the machining cost to the extent possible.

Effect of Cutting Parameters on Surface Roughness in Turning of Bone

2013 ◽  
Vol 845 ◽  
pp. 708-712 ◽  
Author(s):  
P.Y.M. Wibowo Ndaruhadi ◽  
S. Sharif ◽  
M.Y. Noordin ◽  
Denni Kurniawan
Keyword(s):  
Surface Roughness ◽  
Bone Tissue ◽  
Influencing Factor ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Machining Process ◽  
Turning Operation ◽  
Cutting Direction

Surface roughness indicates the damage of the bone tissue due to bone machining process. Aiming at inducing the least damage, this study evaluates the effect of some cutting conditions to the surface roughness of machined bone. In the turning operation performed, the variables are cutting speed (26 and 45 m/min), feed (0.05 and 0.09 mm/rev), tool type (coated and uncoated), and cutting direction (longitudinal and transversal). It was found that feed did not significantly influence surface roughness. Among the influencing factor, the rank is tool type, cutting speed, and cutting direction.

scholarly journals Influence of Chatter of VMC Arising During End Milling Operation and Cutting Conditions on Quality of Machined Surface

1970 ◽  
Vol 2 (1) ◽  
Author(s):  
A.K.M.N. Amin, M.A. Rizal, and M. Razman
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Metal Removal ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
End Mill ◽  
Machined Surface ◽  
Operating Cycle ◽  
Wide Range

Machine tool chatter is a dynamic instability of the cutting process. Chatter results in poor part surface finish, damaged cutting tool, and an irritating and unacceptable noise. Exten¬sive research has been undertaken to study the mechanisms of chatter formation. Efforts have been also made to prevent the occurrence of chatter vibration. Even though some progress have been made, fundamental studies on the mechanics of metal cutting are necessary to achieve chatter free operation of CNC machine tools to maintain their smooth operating cycle. The same is also true for Vertical Machining Centres (VMC), which operate at high cutting speeds and are capable of offering high metal removal rates. The present work deals with the effect of work materials, cutting conditions and diameter of end mill cutters on the frequency-amplitude characteristics of chatter and on machined surface roughness. Vibration data were recorded using an experimental rig consisting of KISTLER 3-component dynamometer model 9257B, amplifier, scope meters and a PC.  Three different types of vibrations were observed. The first type was a low frequency vibration, associated with the interrupted nature of end mill operation. The second type of vibration was associated with the instability of the chip formation process and the third type was due to chatter. The frequency of the last type remained practically unchanged over a wide range of cutting speed.  It was further observed that chip-tool contact processes had considerable effect on the roughness of the machined surface.Key Words: Chatter, Cutting Conditions, Stable Cutting, Surface Roughness.

Tool Wear Analysis of MTConnect Production Data

2021 ◽  
Author(s):  
David Stock ◽  
Aditi Mukhopadhyay ◽  
Rob Potter ◽  
Andy Henderson
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Numerical Control ◽  
Machining Process ◽  
Total Load ◽  
Wear Rates ◽  
Wear Analysis ◽  
Nc Program ◽  
Small Set ◽  
Key Steps

Abstract This paper presents the analysis of data collected using the MTConnect protocol from a lathe with a Computer Numerical Control (CNC). The purpose of the analysis is to determine an estimated cutting tool life and generate a model for calculating a real-time proxy of cutting tool wear. Various streams were used like spindle load, NC program blocks, the mode, execution etc. The novelty of this approach is that no information about the machining process, beyond the data provided by the machine, was necessary to determine the tool’s expected life. This method relies on the facts that a) it is generally accepted cutting loads increase with tool wear and b) that many CNC machines rely on a small set of regularly run CNC programs. These facts are leveraged to extract the total load for each run of each program on the machine, creating a dataset which is a good indicator of tool wear and replacement. The presented methodology has four key steps: extracting cycle metadata from the machine execution data; computing the integrated spindle loads for every cycle; normalizing the integrated spindle loads between different programs; extracting tool wear rates and changes from the resulting dataset. It is shown that the method can successfully extract the signature of tool wear under a common set of circumstances which are discussed in detail.

scholarly journals Development of smart machining system for optimizing feedrates to minimize machining time

2017 ◽  
Vol 5 (3) ◽  
pp. 299-304 ◽  
Author(s):  
Hong-seok Park ◽  
Bowen Qi ◽  
Duck-Viet Dang ◽  
Dae Yu Park
Keyword(s):  
Cutting Force ◽  
Machining Process ◽  
Cnc Machine ◽  
Machining Time ◽  
Virtual Machining ◽  
Milling Operations ◽  
Nc Program ◽  
Machining System ◽  
Optimal Feed ◽  
Smart Machining

Abstract Feedrate optimization is an important aspect of getting shorter machining time and increase the potential of efficient machining. This paper presents an autonomous machining system and optimization strategies to predict and improve the performance of milling operations. The machining process was simulated and analyzed in virtual machining framework to extract cutter-workpiece engagement conditions. Cutting force along the cutting segmentation is evaluated based on the laws of mechanics of milling. In simulation, constraint-based optimization scheme was used to maximize the cutting force by calculating acceptable feedrate levels as the optimizing strategy. The intelligent algorithm was integrated into autonomous machining system to modify NC program to accommodate these new feedrates values. The experiment using optimized NC file which generates by our smart machining system were conducted. The result showed autonomous machining system, was effectively reduced 26%. Highlights The smart machining system was implemented in the CNC machine. Optimal feed rates enhance machine tool efficiency. The smart machining system is reliable to reduce machine time.

An Accuracy-Prediction Model Taking Tool Deformation and Geometric Machine-Tool Error into Consideration

2010 ◽  
Vol 4 (3) ◽  
pp. 235-242 ◽  
Author(s):  
Hirohisa Narita ◽  
◽  
Keiichi Shirase ◽  
Eiji Arai ◽  
Hideo Fujimoto ◽  
...  
Keyword(s):  
Prediction Model ◽  
Machine Tool ◽  
End Milling ◽  
Geometric Error ◽  
Cutting Conditions ◽  
Error Prediction ◽  
Machining Accuracy ◽  
Trial And Error ◽  
Virtual Machining ◽  
Nc Program

Test cutting used to verify cutting conditions and machining accuracy after a numeric control (NC) program is written for end milling the mold and die indispensable to manufacturing is generally effective, because it is based on trial and error. The virtual machining simulator we designed to verify machining accuracy uses an accuracy-prediction model and an error prediction expression for workpieces, integrating machine-tool deformation and geometric error models. We also propose calculation for copying errors to a workpiece.

Model for Economic Optimization of the Tool Life and the Cutting Speed at Drilling of the Steel X5CrNiMo17-12-2

2015 ◽  
Vol 809-810 ◽  
pp. 63-68 ◽  
Author(s):  
Marius Iacob ◽  
Ovidiu Blăjină ◽  
Aurelian Vlase
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
Programming Model ◽  
Cutting Speed ◽  
Machining Process ◽  
Economic Optimization ◽  
Manufacturing Activity ◽  
Nonlinear Programming Model ◽  
The Cost ◽  
Accuracy Of Prediction

In the specialized literature the cost of the machining process has been analyzed using a number of approaches and varying degrees of simplification to determine the optimum tool life and the tool speed. The accuracy of prediction is dependent on the degree of sophistication of the model. The purpose of this paper is the optimization of the cutting tool life and the cutting speed at the drilling of the stainless steels in terms of the minimum machining cost. A more comprehensive nonlinear programming model to minimize the total cost at the drilling of a stainless steel is developed in this paper. The optimum tool life and the associated tool speed are obtained by solving this model. The results can be taken into consideration in the educational studies and in the theoretical technical research. They can be implemented in the manufacturing activity.

Modelling and Optimization of Tool Chip Interface Temperature and Surface Roughness in CNC Dry Turning of EN 24 Steel

2016 ◽  
Vol 16 ◽  
pp. 7-15 ◽  
Author(s):  
Nirmal Kumar Mandal ◽  
Tanmoy Roy
Keyword(s):  
Surface Roughness ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Work Piece ◽  
Substantial Impact

Abstract. Kinetic energy of a machining process is converted into heat energy. The generated heat at cutting tool and work piece interface has substantial impact on cutting tool life and quality of the work piece. On the other hand, development of advanced cutting tool materials, coatings and designs, along with a variety of strategies for lubrication, cooling and chip removal, make it possible to achieve the same or better surface quality with dry or Minimum Quantity Lubrication (MQL) machining than traditional wet machining. In addition, dry and MQL machining is more economical and environment friendly. In this work, 20 no. of experiments were carried out under dry machining conditions with different combinations of cutting speed, feed rate and depth of cut and corresponding cutting temperature and surface roughness are measured. The no. of experiments is determined through Design of Experiments (DOE). Nonlinear regression methodology is used to model the process using Response Surface Methodology (RSM). Multi-objective optimization is carried using Genetic Algorithm which ensures high productivity with good product quality.

Model for Economic Optimization of the Tool Life and the Cutting Speed at Drilling of the Steel 2NiCr185

2015 ◽  
Vol 760 ◽  
pp. 439-444 ◽  
Author(s):  
Ovidiu Blăjină ◽  
Aurelian Vlase ◽  
Marius Iacob
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
Programming Model ◽  
Cutting Speed ◽  
Machining Process ◽  
Economic Optimization ◽  
Manufacturing Activity ◽  
Nonlinear Programming Model ◽  
The Cost ◽  
Accuracy Of Prediction

In the specialized literature the cost of the machining process has been analyzed using a number of approaches and varying degrees of simplification to determine the optimum tool life and the tool speed. The accuracy of prediction is dependent on the degree of sophistication of the model. The purpose of this paper is the optimization of the cutting tool life and the cutting speed at the drilling of the stainless steels in terms of the minimum machining cost. A more comprehensive nonlinear programming model to minimize the total cost at the drilling of a stainless steel is developed in this paper. The optimum tool life and the associated tool speed are obtained by solving this model. The results can be taken into consideration in the educational studies and in the theoretical technical research. They can be implemented in the manufacturing activity.

Effects of End Mill Helix Angle on Accuracy for Machining Thin-Rib Aerospace Component

2013 ◽  
Vol 315 ◽  
pp. 773-777 ◽  
Author(s):  
Raja Izamshah ◽  
M.Yaakob Yuhazri ◽  
Mohd Hadzley ◽  
Mohd Amran Ali ◽  
Sivarao Subramonian
Keyword(s):  
High Performance ◽  
Cutting Tool ◽  
Helix Angle ◽  
Machining Process ◽  
Geometric Feature ◽  
Thin Wall ◽  
End Mill ◽  
Form Errors ◽  
Challenging Tasks ◽  
Monolithic Component

Accuracy of machined component is one of the challenging tasks for manufacturer. In the aerospace industry, machining process is widely used for fabrication of unitized-monolithic component that contains a thin-walled structure. During machining, the cutting forces cause deflection to the thin-wall section, leading to dimensional form errors that cause the finished part to be out of specification or failure. Most of the existing research for machining thin-wall component only concentrated on the process planning and the effects of cutter geometric feature is often neglected. Tool geometric feature has a direct influence on the cutting performance and should not be neglected in the machining consideration. This paper reports on the effect of helix angle on the magnitude of wall deflection. The established effects will be used for the development of high performance cutting tool for specifically machining thin-wall component.

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