High Efficiency Machining for Integral Shaping from Simplicity Materials Using Five-Axis Machine Tools

2016 ◽  
Vol 10 (5) ◽  
pp. 804-812 ◽  
Author(s):  
Makoto Yamada ◽  
◽  
Tsukasa Kondo ◽  
Kai Wakasa
Keyword(s):  
Machine Tools ◽  
High Speed ◽  
High Efficiency ◽  
Cutting Process ◽  
Machining Process ◽  
Rough Machining ◽  
Convex Shape ◽  
Simple Material ◽  
Voxel Model ◽  
Five Axis

In the integrally shaping process from a simple material shape to an objective shape, it is necessary to reduce the time required for the machining process in order to improve cost savings and the effectiveness of mass production. For the purpose of achieving high efficiency in the integral shaping from simplicity materials, we have focused on a rough cutting process that requires the most time in the manufacturing process. The purpose of this research is to propose a method for realizing high-speed rough machining using five-axis machine tools with a voxel model, and confirm the high efficiency of the rough cutting. In this research, we use five-axis controlled machine tools for material machining, and suggest two machining methods for the rough cutting process using the voxel model. The first method derives the tool posture where the cutting removal quantity becomes the maximum; this method also carries out a rough cutting process via 3+2 axis controlled machining. The other method carries a complete convex shape that includes the required shape, and simultaneously machines via five-axis machining based on the complete convex shape. This paper demonstrates the 3+2 axis control machining method that uses the voxel model to perform the rough machining process with high efficiency, and the simultaneous five-axis control machining method that uses a complete convex shape model for rough machining. We confirm the results with a computer simulation and actual machining experiments.

The Research on Cutting Force in High-Speed Milling Process of Aluminum Alloy Impeller

2010 ◽  
Vol 142 ◽  
pp. 11-15 ◽  
Author(s):  
Y.B. Liu ◽  
C. Zhao ◽  
X. Ji ◽  
Ping Zhou
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
High Speed ◽  
Test Method ◽  
Cutting Process ◽  
Machining Process ◽  
High Speed Milling ◽  
High Speed Cutting ◽  
Five Axis ◽  
Cutting Path

High-speed cutting process of cutting force influence variables and variation and ordinary speed cutting are obviously different, in order to study the high-speed cutting process of different parameters on the effect of cutting force, based on five axis high-speed NC machining center, using multi-factor orthogonal test method for high speed milling of aluminum alloy impeller conducted experiments. It was analyzed that cutting force influence factors of 5-axises blade machining process. A private clamp was designed and produced, to measure the cutting force of machining process. It was observe that distribution of 3-dimension cutting forces in cutting path. It was found that the distribution rule of cutting force. With the experiment study on cutting force when high speed cutting aluminum cuprum, the influence disciplinarian of each cutting parameter on cutting force was obtained.

Ultra-High Speed Grinding Using a CBN Wheel for a Mirror-Like Surface Finish

2005 ◽  
Vol 291-292 ◽  
pp. 67-72 ◽  
Author(s):  
M. Ota ◽  
T. Nakayama ◽  
K. Takashima ◽  
H. Watanabe
Keyword(s):  
Surface Finish ◽  
High Speed ◽  
High Efficiency ◽  
Ground Surface ◽  
Machining Process ◽  
Grinding Wheel ◽  
Cbn Wheel ◽  
Ultra High Speed ◽  
High Speed Grinding ◽  
Grinding Conditions

There are strong demands for a machining process capable of reducing the surface roughness of sliding parts, such as auto parts and other components, with high efficiency. In this work, we attempted to grind hardened steel to a mirror-like surface finish with high efficiency using an ultra-high speed grinding process. In the present study, we examined the effects of the work speed and the grinding wheel grain size in an effort to optimize the grinding conditions for accomplishing mirror-like surface grinding with high efficiency. The results showed that increasing the work speed, while keeping grinding efficiency constant, was effective in reducing the work affected layer and that the grinding force of a #200 CBN wheel was lower than that of a #80 CBN wheel. Based on these results, a high-efficiency grinding step with optimized grinding conditions was selected that achieved excellent ground surface quality with a mirror-like finish.

Research and Application on High Efficiency Reversible Cutting Technique

2004 ◽  
Vol 471-472 ◽  
pp. 825-829
Author(s):  
Wen Ge Wu ◽  
Si Qin Pang ◽  
Qi Xun Yu
Keyword(s):  
High Efficiency ◽  
Cutting Tool ◽  
Handling Time ◽  
Cutting Parameters ◽  
Machining Process ◽  
Processing Route ◽  
Rough Machining ◽  
Machined Surface ◽  
Primary Motion ◽  
The Way

Reversible cutting method is a research thesis proposed to shorten processing route, decrease tool number and handling time, increase machining efficiency. There are three movement ways, i.e. reversible feed motion, reversible primary motion and reversible composite motion. Primary motion is done by workpiece, conventional or reversible feed motion is done by cutting tool in the way of reversible feed motion, e.g. turning. Cutting velocity is passed to cutting tool, clockwise or anti-clockwise cutting movement is done by cutting tool in the way of reversible primary motion, e.g. milling, shaping, drilling (spade drill), reaming. Primary and feed motions are all reversible in composite motion, e.g. turn-milling. Chip deformation and machined surface with reversible finishing is discussed. A mechanical analysis is carried out to the workpiece deformation of slender shaft turning in normal direction and reversible direction. The result has been verified by experiments. Experimental data for the range of cutting parameters tested showed that the reversible fine machining produce the compressive residual stresses at the surface, which are critical in the performance of the machined components. Experimental research indicted that the results of micro-hardness of reversible fine machining technique are smaller than that of general fine machining show that decreased plastic deformation of the surface layer and work-hardening. It can be adopted such planning which rough machining during advance stroke and fine machining during return stroke in machining process.

An Efficient Volumetric-Error Measurement Method for Five-Axis Machine Tools

2005 ◽  
Author(s):  
Shih-Ming Wang ◽  
Han-Jen Yu ◽  
Hung-Wei Liao
Keyword(s):  
Machine Tools ◽  
Measurement Method ◽  
Degrees Of Freedom ◽  
High Efficiency ◽  
Low Cost ◽  
Volumetric Errors ◽  
Different Types ◽  
Measurement Methodology ◽  
Simple Measurement ◽  
Five Axis

Accurate measurement of volumetric errors plays an important role for error compensation for multi-axis machines. The error measurements for volumetric errors of five-axis machines are usually very complex and costly than that for three-axis machines. In this study, a direct and simple measurement method using telescoping ball-bar system for volumetric errors for different types of five-axis machines was developed. The method using two-step measurement methodology and incorporating with derived error models, can quickly determine the five degrees-of-freedom (DOF) volumetric errors of five-axis machine tools. Comparing to most of the current used measurement methods, the proposed method provides the advantages of low cost, high efficiency, easy setup, and high accuracy.

Vibrations in High Speed Boring Process of Bioengineering Polymers

2016 ◽  
Vol 856 ◽  
pp. 125-128
Author(s):  
Athanasios G. Mamalis ◽  
G. Tokhtar ◽  
Sergiy Lavrynenko
Keyword(s):  
High Speed ◽  
Cutting Process ◽  
Machining Process ◽  
Effective Alternative ◽  
High Quality ◽  
High Speed Cutting ◽  
Operation Control

At the present time the polymers are reliable and effective alternative to more traditional materials for many applications especially for bioengineering. Achievement of high quality biopolymeric components demands particular conditions for the machining process and its control. This report is devoted to method for operation control of the high speed cutting process by measurement of vibrating acceleration.

Next-Generation, Super-Hard-to-Process Substrates and Their High-Efficiency Machining Process Technologies Used to Create Innovative Devices

2018 ◽  
Vol 12 (2) ◽  
pp. 145-153 ◽  
Author(s):  
Toshiro Doi ◽  
Keyword(s):  
Chemical Mechanical Polishing ◽  
High Speed ◽  
High Efficiency ◽  
High Pressure Processing ◽  
Machining Process ◽  
Next Generation ◽  
Plasma Chemical ◽  
Plasma Fusion ◽  
Ultra Precision ◽  
Efficient Processing

SiC, GaN, and diamond are known as super-hard-to-process substrate for next-generation green devices. In this paper, we report on some breakthrough in developing highly efficient processing for such hard-to-process materials, for which we propose improvements in conventional processing, and innovative processing. As part of our project, we developed a “dilatancy pad®” that can efficiently produce high-quality surfaces as well as a high-rigidity, high-speed and high-pressure processing machine. We also designed and prototyped “plasma fusion CMP®,” which is an innovative processing technology fusing CMP (Chemical Mechanical Polishing) with P-CVM (Plasma Chemical Vaporization Machining) to machine super-hard diamond substrates that are considered indispensable for future devices. Before the advent of “singularities” by 2045, super-hard-to-process substrates and ultra-precision polishing technology will become more and more essential.

The Research of Five-Axis NC High Efficient Machining Technology for UAV Integral Impeller

2014 ◽  
Vol 598 ◽  
pp. 189-193
Author(s):  
Hui Zhao ◽  
Yu Jun Cai ◽  
Guo He Li
Keyword(s):  
Process Analysis ◽  
Coordinate Measuring Machine ◽  
Machining Process ◽  
Machining Parameters ◽  
Program Optimization ◽  
Cnc Machine ◽  
Rough Machining ◽  
High Efficient ◽  
Measuring Machine ◽  
Five Axis

In this paper, a very detailed process analysis for UAV integral impeller was made. According to the specific processing requirements, the appropriate CNC machine, blank and cutting tools have been choosing. In the rough machining process, various machining strategies have been used for comparing and analyzing, finally a more efficient roughing method with the accurate machining parameters will be obtained. At the same time the machining method have been improved and the processing parameters also have been determined in the semi-finishing process. Through the simulation processing in VERICUT, the possibility of the existence of interference which is usually occurred in the actual processing can be ruled out and the program optimization will be finished in the meantime. Finally, using intelligent three-coordinate measuring machine the consequence will be verified and inspected in the actual machining process.

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