Supporting Method for Thin Parts Having Curved Surfaces – Improvement of End Milling Accuracy by Using Low-Melting Point Alloy and Elastomer Support –

2019 ◽  
Vol 13 (1) ◽  
pp. 92-100 ◽  
Author(s):  
Akinori Saito ◽  
Shinya Kato ◽  
Mitsuo Nagao ◽  
◽  
Keyword(s):  
Melting Point ◽  
Cutting Force ◽  
Turbine Blade ◽  
End Milling ◽  
High Accuracy ◽  
Curved Surface ◽  
Machining Accuracy ◽  
Curved Surfaces ◽  
Mechanical Parts ◽  
Experimental Part

Many mechanical parts have complicated and delicate shapes for improving their functionality and designability. To machine thin parts with high accuracy, it is necessary to reduce the cutting force induced on the workpiece or to clamp the workpiece optimally. Generally, cores are placed in the workpiece to fix it firmly at the production site. However, the cores must be adjusted precisely in accordance with the shape of the workpiece. A low-point melting alloy can be conveniently used instead of the cores. In this study, the influence of the supporting method for thin parts having a curved surface using a low-melting point alloy on machining accuracy is experimentally investigated. The turbine blade is selected as the experimental part. The shape is produced via end milling. The experimental results indicate that a low-melting point alloy can be closely fitted to the supporting curved surface of the turbine blade because the volume of the low-melting point alloy increases in the solidification. However, the machining accuracy is degraded when the turbine blade is deformed owing to the characteristics of the low-melting point alloy. A support method using the low-melting point alloy and an elastomer support is proposed to improve the machining accuracy. The effectiveness of the proposed method is experimentally confirmed.

scholarly journals Improvement of Machining Accuracy Through Support Method Using Magnetic Elastomer

2021 ◽  
Vol 15 (4) ◽  
pp. 404-412
Author(s):  
Nobuaki Usui ◽  
Akinori Saito ◽  
◽  
Keyword(s):  
Melting Point ◽  
Cutting Force ◽  
High Accuracy ◽  
Machining Accuracy ◽  
Information Communication ◽  
Mechanical Parts

Many mechanical parts used for various purposes, including medicine and information communication, have complicated and thin shapes owing to their functions and designs. To machine thin parts with high accuracy, it is necessary to reduce the cutting force induced on the workpiece or clamp the workpiece in an optimal manner. In this study, a support method capable of supporting the strength by using a magnetic elastomer is proposed. To test the effectiveness of the proposed support method, the use of the approach when applying a magnetic elastomer was compared with a method using a core, the low-melting point alloy, the low-melting point alloy and the elastomer. The effectiveness of the proposed method was clarified experimentally.

scholarly journals Hilbert-Huang Transform Analysis of Machining Stability in Ball-Nose End-Milling of Curved Surface

2020 ◽  
Vol 14 (3) ◽  
pp. 500-511
Author(s):  
Muizuddin Azka ◽  
Keiji Yamada ◽  
Mahfudz Al Huda ◽  
Kyosuke Mani ◽  
Ryutaro Tanaka ◽  
...  
Keyword(s):  
Cutting Force ◽  
Inclination Angle ◽  
End Milling ◽  
Curved Surface ◽  
Hilbert Huang Transform ◽  
Time Frequency ◽  
Machining Errors ◽  
Cutting Velocity ◽  
Cylindrical Workpiece ◽  
The Stability

This paper investigates the machining stability in ball-end-milling of curved surface in which the inclination of tool continuously changes. Initially, the influence of inclination angle is geometrically investigated on the parameters such as immersion angle and cutting velocity. Then, the paper presents the stability lobe diagrams of the process. Curved surface milling is simulated by slot milling on a cylindrical workpiece using a ball-end-mill to obtain the cutting force and vibration, which are used for fast-Fourier transform and Hilbert-Huang transform (HHT) analyses. Experimental results show that the cutting force increases, and the stability becomes worse with the inclination angle, while the machining errors decrease with the inclination. The vibration analysis showed that the HHT can detect the transition from stable to unstable during milling of curved surface in the time-frequency plots.

Statistical Approach for the Development of Tangential Cutting Force Model in End Milling of Ti6Al4V

2011 ◽  
Vol 264-265 ◽  
pp. 1160-1165
Author(s):  
Anayet Ullah Patwari ◽  
A.K.M. Nurul Amin ◽  
Waleed Fekry Faris
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
End Milling ◽  
Dynamic Change ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Force Model ◽  
Machining Parameters ◽  
Cutting Force Model

Dynamic change in cutting force is one of the major causes of chatter formation in metal cutting which affect machining accuracy. Thus, accurate modeling of cutting force is necessary for the prediction of machining performance and determination of the mechanisms and machining parameters that affect the stability of machining operations. The present paper discusses the development of a mathematical model for predicting the tangential cutting force produced in endmilling operation of Ti6Al4V. The mathematical model for cutting force prediction has been developed in terms of the input cutting parameters cutting speed, feed rate, and axial depth of cut using response surface methodology (RSM). Effects of all the individual cutting parameters on cutting force as well as their interactions are investigated in this study. Central composite design was employed in developing the cutting force model in relation to the primary cutting parameters. The experimental results indicate that the proposed mathematical models suggested could adequately describe the performance indicators within the limits of the factors that are being investigated.

Cutting force prediction in end milling of curved surfaces based on oblique cutting model

2016 ◽  
Vol 89 (1-4) ◽  
pp. 1025-1038 ◽  
Author(s):  
Zhi-Wen Luo ◽  
Wen-Xiang Zhao ◽  
Li Jiao ◽  
Tao Wang ◽  
Pei Yan ◽  
...  
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Curved Surfaces ◽  
Cutting Force Prediction ◽  
Force Prediction ◽  
Oblique Cutting ◽  
Cutting Model

Research on the Tool Wear Mechanism of Cemented Carbide Ball End Mill Machining Titanium Alloy

2016 ◽  
Vol 836-837 ◽  
pp. 318-325 ◽  
Author(s):  
Yu Hua Zhang ◽  
Shu Cai Yang ◽  
Chuang Feng
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
High Efficiency ◽  
Convex Surface ◽  
End Milling ◽  
Cutting Parameters ◽  
Least Square ◽  
Curved Surface ◽  
Force Model ◽  
Mill Machining

In order to achieve the high efficiency machining of titanium, the cutting force model is verified through the cutting experimental platform in machining cant and curved surface with ball end milling. And then the influence of cutting parameters and surface curvature on cutting force and tool wear are investigated. Finally, the prediction model of tool wear is established based on the orthogonal test and the least square method. This study proposes that the tool wear and each tooth feeding have a major impact on cutting force and that the convex surface from a small curvature to larger and the concave surface from a large curvature to smaller can effectively improve the life of tool in machining curved surface.

Estimation of Cutter Deflection Based on Study of Cutting Force and Static Flexibility

2015 ◽  
Vol 138 (4) ◽  
Author(s):  
Xianyin Duan ◽  
Fangyu Peng ◽  
Rong Yan ◽  
Zerun Zhu ◽  
Kai Huang ◽  
...  
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Chip Thickness ◽  
Machining Accuracy ◽  
Tool Orientation ◽  
Surface Machining ◽  
Cutter Deflection ◽  
Geometrical Constraints ◽  
Machining System ◽  
Five Axis

In the tool orientation planning for five-axis sculptured surface machining, the geometrical constraints are usually considered. Actually, the effect of nongeometrical constraints on tool orientation planning is also important. This paper studied one nongeometrical constraint which was cutting force induced static deflection under different tool orientations, and proposed a cutter deflection model based on that. In the study of the cutting force, the undeformed chip thickness in filleted end milling was modeled by geometrical analysis and coordinate transformation of points at the cutting edge. In study of static flexibility of multi-axis machine, static flexibility of the entire machining system was taken into consideration. The multi-axis machining system was divided into the transmission axes-handle (AH) end and the cutting tool end. The equivalent shank method was developed to calculate the static flexibility of the AH end. In this method, static flexibility anisotropy of the AH end was considered, and the equivalent lengths of the AH end were obtained from calibration experiments. In cutter deflection modeling, force manipulability ellipsoid (FME) was applied to analyze the static flexibility of the AH end in arbitrary directions. Based on the synthetic static flexibility and average cutting force, cutter deflections were derived and estimated through developing program realization. The predicted results were compared with the experimental data obtained by machining 300 M steel curved surface workpiece, and a good agreement was shown, which indicated the effectiveness of the cutter deflection model. Additional experiments of machining flat workpiece were performed, and the relationship of cutter deflections and tool orientations were revealed directly. This work could be further employed to optimize tool orientations for suppressing the surface errors due to cutter deflections and achieving higher machining accuracy.

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