scholarly journals High-speed End Milling of Extruded Aluminum Alloys Using Articulated Robot

1999 ◽  
Vol 11 (5) ◽  
pp. 399-403
Author(s):  
Kazunori Shimizu ◽  
◽  
Shin-ichi Matsuoka ◽  
Nobuyuki Yamazaki ◽  
Yoshinari Oki ◽  
...  
Keyword(s):  
Aluminum Alloys ◽  
Cutting Force ◽  
High Frequency ◽  
High Speed ◽  
End Milling ◽  
Small Diameter ◽  
Work Piece ◽  
High Frequency Vibration ◽  
Low Stiffness ◽  
Articulated Robot

This study describes the end milling operation using an articulated robot that is the new machining for extruded aluminum alloys. The most important characteristic of this operation is using the small diameter of endmill and the high-speed spindle in order to reduce a cutting force and improve the low stiffness of an articulated robot. However, the behavior of end milling with super-fast spindle speed for extruded aluminum alloys was still unclear. In this paper, in order to clear it, the basic end milling experiments and structural analysis were done. Consquently, it was proved that the high frequency vibration proper to high-speed end milling had a close relation to the stiffness (natural frequency) of machine tools or work piece, and great affected the cutting force and the cutting surface. On the other hand, it was confirmed that the articulated robot had few effects on the high frequency vibration of end milling because of low stiffness, and that the cutting force was 50 to 70% down compared with the fluting machine. Therefore, it is thought that the end milling using an articulated robot is effective for the improvement of high-speed end milling performance.

Monitoring of Cutting State in End-Milling Based on Measurement of Tool Behavior Using CCD Image

2019 ◽  
Vol 13 (1) ◽  
pp. 133-140 ◽  
Author(s):  
Shinichi Yoshimitsu ◽  
◽  
Daiki Iwashita ◽  
Kenji Shimana ◽  
Yuya Kobaru ◽  
...  
Keyword(s):  
Cutting Force ◽  
Process Monitoring ◽  
High Speed ◽  
End Milling ◽  
Small Diameter ◽  
Ccd Camera ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Tool Deflection ◽  
Spindle Power

To date, various in-process monitoring and measuring techniques for milling have been proposed; these are based on factors such as spindle power, cutting force, and vibration. However, the spindle power and cutting force in small-diameter milling processes are too small, thereby rendering these methods ineffective. This study aims to develop an in-process monitoring system of the cutting state, and thus, prevent tool breakage in milling when using a small-diameter tool. Our previous study showed that this monitoring technique is based on the analysis of the tool projection image by a CCD camera. It enables a precise measurement of tool deflection during high-speed milling. In this study, we apply this system to the measurement of tool deflection in end milling under different cutting conditions, including tool type, machining shape, workpiece, and feed rate. Moreover, we examine the relationship between tool deflection and cutting conditions. The results clarify that this system enables in-process monitoring of tool deflection. The measured tool deflection with this system is influenced by the cutting condition. In addition, the tool deflection shows a periodical change in one turn, which seems to be related to the number of tool edges.

scholarly journals High-Speed End Milling of Aluminum Alloys Using Articulated Robot. Improvement of Machining Speed.

1999 ◽  
Vol 65 (636) ◽  
pp. 3465-3470
Author(s):  
Shin-ichi MATSUOKA ◽  
Kazunori SHIMIZU ◽  
Nobuyuki YAMAZAKI ◽  
Yoshinari OKI
Keyword(s):  
Aluminum Alloys ◽  
High Speed ◽  
End Milling ◽  
Machining Speed ◽  
Articulated Robot

Numerical Simulation of Cutting Force in High Speed Machining of Inconel 718

2020 ◽  
Vol 856 ◽  
pp. 43-49
Author(s):  
Santosh Kumar Tamang ◽  
Nabam Teyi ◽  
Rinchin Tashi Tsumkhapa
Keyword(s):  
Cutting Force ◽  
Inconel 718 ◽  
High Speed ◽  
Experimental Results ◽  
Machining Process ◽  
Experimental Result ◽  
Work Piece ◽  
High Speed Machining ◽  
Numerical Result ◽  
3D Software

Machining is one of the major manufacturing processes that converts a raw work piece of arbitrary size into a finished product of definite shape of predetermined size by suitably controlling the relative motion between the tool and the work. Lately, machining process is shifting towards high speed machining (HSM) from conventional machining to improve and efficiently increase production, and towards dry machining from excessive coolant used wet machining to improve economy of production. And the tools used are mostly hardened alloys to facilitate HSM. The work piece materials are continually improving their properties by emergence and development of newer and high resistive super alloys (HRSA). In this paper an attempt has been made to validate an experimental result of cutting force obtained by performing HSM on an HRSA Inconel 718, by comparing it with the numerical result obtained by simulating the same setting using DEFORM 3D software. Based on the comparison it is found that the simulated results exhibit close proximity with the experimental results validating the experimental results and the effectiveness of the software.

scholarly journals Research into Correlation between the Lubrication Mode of Contact Surfaces and Dynamic Parameters of Turbo-Generator Transmissions

2019 ◽  
Vol 2019 ◽  
pp. 1-10
Author(s):  
Marek Kočiško ◽  
Petr Baron ◽  
Monika Telíšková ◽  
Jozef Török ◽  
Anna Bašistová
Keyword(s):  
Acoustic Emission ◽  
High Frequency ◽  
High Speed ◽  
Oil Quality ◽  
The State ◽  
Dynamic Parameters ◽  
High Frequency Vibration ◽  
Turbo Generator ◽  
Friction Mode ◽  
Contact Surfaces

The paper presents the results of an experimental study aimed at assessing the correlation between the measurement of dynamic parameters (vibration, high-frequency vibration, and acoustic emission) and the analysis of friction mode and the state of lubrication of the contact surfaces of two gearboxes in the turbo-generator assembly (high-speed single-body steam turbine—gearbox—generator) with the transmission power of no more than 50 MW. The analysis confirmed the assumption of a significant correlation of the monitored high-frequency vibration signal with the unsatisfactory engagement of the gear teeth. Through vibration analysis, an increased level of the tooth vibration component and vibration multiples with increased acoustic emission were identified in gearbox operation. The gear oil of one of the gearboxes examined showed a loss of additive elements in the real operation of the contact surfaces of the teeth engagement. The trend analysis confirmed the complexity of the monitored transmission operation in terms of the friction mode and the influence of the oil quality on the state of the tooth flank microgeometry.

Comparative Study on Cutting Force Simulation Using DEFORM 3D Software during High Speed Machining of Ti-6Al-4V

2020 ◽  
Vol 856 ◽  
pp. 50-56
Author(s):  
Kundan Kumar Prasad ◽  
Santosh Kumar Tamang ◽  
M. Chandrasekaran
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Temperature ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Work Piece ◽  
High Speed Machining ◽  
3D Software ◽  
Deform 3D

The finite element-based machining simulations for evaluation/computation of different machining responses (i.e., cutting temperature, tool wear, cutting force, and power/energy consumption) are investigated by number of researchers. In this work, finite element machining simulation was performed to obtain knowledge about cutting forces during machining of hard materials. Titanium alloy (Ti-6Al-4V) has been increasingly used in aerospace and biomedical applications due to high toughness and good corrosion resistance. The high speed machining (HSM) simulation of Ti-6Al-4V work-piece using carbide tool coated with TiCN has been conducted with different combination of cutting conditions for prediction of main cutting force (Fz). The simulated result obtained from Deform 3D software is validated with experimental result and it was found that the result found in good agreement. The parametric variation shows that depth of cut and feed are influencing parameters on cutting force.

An Experiment-Based Investigation on Characteristic and Model of Milling Forces during End-Milling Aluminum Alloy

2014 ◽  
Vol 494-495 ◽  
pp. 602-605
Author(s):  
Zeng Hui An ◽  
Xiu Li Fu ◽  
Ya Nan Pan ◽  
Ai Jun Tang
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
End Milling ◽  
Influence Factors ◽  
Cutting Speed ◽  
Cutting Depth ◽  
Milling Forces

Cutting forces is one of the important physical phenomena in metal cutting process. It directly affects the surface quality of machining, tool life and cutting stability. The orthogonal experiments of cutting forces and influence factors with indexable and solid end mill were accomplished and the predictive model of milling force was established during high speed end milling 7050-T7451 aluminum alloy. The paper makes research mainly on the influence which the cutting speed, cutting depth and feed have on the cutting force. The experimental results of single factor showed that the cutting forces increase earlier and drop later with the increase of cutting speed, and the cutting speed of inflexion for 7050-T7451 is 1100m/min. As axial cutting depth, radial cutting depth and feed rate increase, the cutting force grows in different degree. The cutting force is particularly sensitive to axial cutting depth and slightly to the radial cutting depth.

Parametric Design of Ball-End Milling Tools for High Speed Milling

2014 ◽  
Vol 800-801 ◽  
pp. 484-488
Author(s):  
Cai Xu Yue ◽  
Fu Gang Yan ◽  
Lu Bin Li ◽  
Hai Yan You ◽  
Qing Jie Yu
Keyword(s):  
High Speed ◽  
Parametric Design ◽  
End Milling ◽  
Complex Surface ◽  
Cutting Parameters ◽  
Secondary Development ◽  
Design System ◽  
Work Piece ◽  
Milling Cutter ◽  
Ball End Milling

Ball-end milling cutter is widely used in machining complex surface parts , and it is need to select a reasonable geometric parameters of the milling cutter for different work piece materials and shapes and cutting parameters. This article is based on UG secondary development technology to develop the Multi-blade ball-end milling cutter parametric design system, it is automatic, fast and efficient to build all kinds of parameters of double, three and four blades ball-end milling cutter model required for user.

scholarly journals Influence of the Cut Axial Depth on Surface Roughness at High-Speed Milling of Thin-Walled Workpieces

2021 ◽  
Vol 20 (2) ◽  
pp. 127-131
Author(s):  
A. I. Germashev ◽  
V. A. Logominov ◽  
S. I. Dyadya ◽  
Y. V. Kozlova ◽  
V. A. Krishtal
Keyword(s):  
High Speed ◽  
End Milling ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Work Piece ◽  
Natural Vibration Frequency ◽  
High Speed Milling ◽  
Wide Range ◽  
Thin Walled ◽  
Axial Depth

The paper presents the results of research on the dynamics of end milling of thin-walled work-pieces having complex geometric shapes. Since the milling process with shallow depths of cut is characterized by high intermittent cutting, the proportion of regenerative vibrations decreases, and the effect of forced vibrations on the dynamics of the process, on the contrary, increases. The influence of  axial depth of cut on the vibrations arising during processing, and roughness of the processed surface have been studied in paper.  The experiments have been carried out in a wide range of changes in the spindle speed at different axial cutting depths.  Vibrations of a thin-walled work-piece  have been recorded with an inductive sensor and recorded in digital form. Then an oscillogram has been used to estimate the amplitude and frequency of oscillations. The profilograms of the machined surface have been analysed. Roughness has been evaluated by the parameter Ra. The results have shown similar relationships for each of the investigated axial cutting depths. The worst cutting conditions  have been observed when the natural vibration frequency coincided with the tooth frequency or its harmonics. It is shown that the main cause of vibrations in high-speed milling  is forced rather than regenerative vibrations. Increasing the axial depth of cut at the same spindle speed increases the vibration amplitude. However, this does not significantly affect the roughness of the processed surface in cases when it comes to vibration-resistant processing.

Cutting Force and Friction Modelling in High Speed End-Milling

2015 ◽  
Author(s):  
Sunday J. Ojolo ◽  
Olumuwiya Agunsoye ◽  
Oluwole Adesina ◽  
Gbeminiyi M. Sobamowo
Keyword(s):  
Temperature Field ◽  
Temperature Distribution ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Process ◽  
Machining Process ◽  
Work Piece

Temperature field in metal cutting process is one of the most important phenomena in machining process. Temperature rise in machining directly or indirectly determines other cutting parameters such as tool life, tool wear, thermal deformation, surface quality and mechanics of chip formation. The variation in temperature of a cutting tool in end milling is more complicated than any other machining operation especially in high speed machining. It is therefore very important to investigate the temperature distribution on the cutting tool–work piece interface in end milling operation. The determination of the temperature field is carried out by the analysis of heat transfer in metal cutting zone. Most studies previously carried out on the temperature distribution model analysis were based on analytical model and with the used of conventional machining that is continuous cutting in nature. The limitations discovered in the models and validated experiments include the oversimplified assumptions which affect the accuracy of the models. In metal cutting process, thermo-mechanical coupling is required and to carry out any temperature field determination successfully, there is need to address the issue of various forces acting during cutting and the frictional effect on the tool-work piece interface. Most previous studies on the temperature field either neglected the effect of friction or assumed it to be constant. The friction model at the tool-work interface and tool-chip interface in metal cutting play a vital role in influencing the modelling process and the accuracy of predicted cutting forces, stress, and temperature distribution. In this work, mechanistic model was adopted to establish the cutting forces and also a new coefficient of friction was also established. This can be used to simulate the cutting process in order to enhance the machining quality especially surface finish and monitor the wear of tool.

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