scholarly journals An Integrated Curvature Surface Inspection and Prediction System for 5-Axis Synchronization Machining

2021 ◽  
Author(s):  
Chung-Feng Jeffrey Kuo ◽  
Wei-Han Weng
Keyword(s):  
Surface Roughness ◽  
Machine Tool ◽  
Surface Quality ◽  
Surface Texture ◽  
High Speed ◽  
Free Form ◽  
Inspection System ◽  
Prediction System ◽  
Roughness Prediction ◽  
Five Axis

Abstract There is an urgent demand for free form products in industry at the present time because of their superior appearance and the wide variety of functions they perform. Five-axis high-speed CNC machining technology has developed to satisfy this demand, but further improvement in surface quality metric inspection technology is the big challenge it now faces. In this study, the effects of jerk on the performance of five-axis synchronous high-speed CNC ball nose end mills on a freeform turbine mold were investigated. The relationships of characteristics of the images of 14 jerk-cluster finished workpieces with different jerk setting values were established, allowing surface texture features to be analyzed and surface roughness predicted. In addition, machine learning methods were integrated with the surface feature analysis to construct a virtual machining module that acts as a performance prediction system, merging the virtual machine tool functions, surface texture processor and AI roughness prediction processor. Using the geometric information of the workpiece, cutting parameters and machine tool parameters as inputs, product performance metrics combining surface roughness and machining time can be predicted as outputs of the system. The integrated system provides users with a way to evaluate manufacturing performance before performing actual operations and to reduce test time for cutting parameter development. The model is suitable for complex surface finishes as well as for the production of small batches with high parametric variance. In addition, the partial set of image processing and roughness prediction modules can be used alone as an effective intelligent surface quality inspection system.

Research on Surface Roughness Prediction Model for High-Speed Milling Inclined Plane of Hardened Steel

2010 ◽  
Vol 97-101 ◽  
pp. 2044-2048 ◽  
Author(s):  
Yuan Ling Chen ◽  
Bao Lei Zhang ◽  
Wei Ren Long ◽  
Hua Xu
Keyword(s):  
Surface Roughness ◽  
Prediction Model ◽  
High Speed ◽  
Hardened Steel ◽  
Prediction Errors ◽  
Inclined Plane ◽  
Workpiece Surface ◽  
Factors Influencing ◽  
Generalized Regression Neural Networks ◽  
Roughness Prediction

As the factors influencing the workpiece surface roughness is complexity and uncertainty, according to orthogonal experimental results, the paper established Empirical regression prediction model and generalized regression neural networks (GRNN) for prediction of surface roughness when machining inclined plane of hardened steel in high speed , moreover, compared their prediction errors. The results show that GRNN model has better prediction accuracy than empirical regression prediction model and can be better used to control the surface roughness dynamically.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

Surface Quality Prediction in Case of Steep Free Form Surface Milling

2016 ◽  
Vol 686 ◽  
pp. 119-124 ◽  
Author(s):  
Balázs Mikó
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Tool Path ◽  
Complex Geometry ◽  
Cutting Parameters ◽  
Free Form ◽  
Milling Cutter ◽  
Good Surface ◽  
2.5D Milling ◽  
Free Form Surfaces

The machining of free form surfaces is a current and important issue in die and mould industry. Beside the complex geometry, an accurate and productive machining and good surface quality are needed. The finishing milling carried out by a ball-end or toroid milling cutter defines the surface quality, which is characterized by the surface roughness and the tool path trace. The surface quality is defined by the properties of the milling cutter, the type of surface and its position, as well as the cutting parameters. This article focuses on the z-level milling of steep surfaces by 2.5D milling strategy. The importance of the different elements of the tool path is presented, the effect of cutting parameters is investigated, and a formula to predict the surface roughness is suggested.

Investigation on surface quality of high-speed cutting titanium alloy Ti6Al4V based on Split-Hopkinson pressure bar

2020 ◽  
Vol 234 (10) ◽  
pp. 1293-1301 ◽  
Author(s):  
Zhanfei Zhang ◽  
Zengqiang Wang ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Yifeng Xiong
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Surface Quality ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Hopkinson Pressure Bar ◽  
High Speed Cutting ◽  
Pressure Bar

High-speed cutting technology has the characteristics of high material removal rate and excellent processing quality. To investigate the surface quality of high-speed cutting Ti6Al4V alloy, the orthogonal cutting experiment is the cutting device based on improved Split-Hopkinson pressure bar carried out with a cutting speed of about 7–16 m/s. Surface roughness, residual stress and three-dimensional surface topography are examined to characterize the surface quality. And the chip geometry parameters are measured to analyze the formation mechanism of surface topography. The result shows that cutting force and surface roughness increase rapidly with the increase in depth of cut. In the meantime, the periodic microwaves appeared on the machined surface, and their amplitudes increase with the increase in depth of cut. However, surface roughness, residual stress and microwave amplitude all decrease with the increase in cutting speed. Moreover, it is found that the evolution trend of chip thickness and surface roughness with cutting parameters is very similar. Therefore, it can be inferred that there is a strong relationship between surface topography and chip morphology.

Electric Machine Technology Needs Analysis of the Linear Motor

2014 ◽  
Vol 490-491 ◽  
pp. 1138-1141
Author(s):  
Yu Ping Zhao ◽  
Yu Hai Xu
Keyword(s):  
Control System ◽  
Machine Tool ◽  
High Speed ◽  
Linear Motor ◽  
Test System ◽  
Electric Machine ◽  
Special Role ◽  
Technical Requirements ◽  
Drive Control ◽  
Five Axis

This article is in view of the linear motor aspects of application development in the field of electric machine tool equipment technical requirements analysis, linear motor with its high speed and high acceleration transmission has been in processing center, CNC milling machine, lathe, grinding machine, compound machine, laser is widely used in machine tools and heavy machine tool, in the aerospace, automotive, mold, energy, general machinery in areas such as plays a special role. Linear motor has precise control test system, reasonable matching of the technical indicators, to make it on the electric machine driven by linear motor can realize stable precision mobile and linear motor used for electric spark machine tool is another innovative application achievement of the modern advanced manufacturing industry. Domestic electric machine mostly adopts five axis NC gear rack drive control system, using the linear motor drive control system was still in the stage of research, to promote the linear motor is widely used in the field of electric machine, and the demand analysis.

Effect of the Working Diameter to the Surface Quality in Free-Form Surface Milling

2013 ◽  
Vol 581 ◽  
pp. 372-377 ◽  
Author(s):  
Balázs Mikó ◽  
Jozef Beňo
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Free Form ◽  
Effective Diameter ◽  
Test Part ◽  
Free Form Surface ◽  
Free Form Surfaces

The article presents the changing of the working diameter (effective diameter) and its effect to the surface roughness based on milling experiments of a test part in 3D milling of free-form surfaces. The position of the surface and the step depth determine the effective diameter, in case of constant revolution of the tool, the actual cutting speed and the minimal removable chip thickness will change. The article presents the result of the application of the constant cutting speed and feed per tooth.

Toolpath Generation Method Based on Control Characteristics of Machine Tool for High-Speed and High-Accuracy Machining

2012 ◽  
Vol 6 (6) ◽  
pp. 697-703 ◽  
Author(s):  
Kosuke Saito ◽  
◽  
Hideki Aoyama ◽  
Noriaki Sano ◽  
Keyword(s):  
Machine Tool ◽  
Surface Quality ◽  
High Speed ◽  
Linear Interpolation ◽  
Machining Accuracy ◽  
Drive Control ◽  
Interpolation Problems ◽  
Nc Machine ◽  
Nc Machine Tools ◽  
Time Required

Drive control of NC machine tools is based on linear interpolation. When curved surfaces are machined using linear interpolation, problems arise with the feedrate not reaching the command feedrate, machining accuracy and surface quality decreasing, etc. In order to solve such problems, a method for generating a toolpath based on the control characteristics of a machine tool is proposed. The effectiveness of the proposed method is confirmed through simulations and experiments. It is found that the proposed method can reduce the cutting time to approximately 50% of the time required when conventional CAM systems are used. The proposed method also improves surface quality.

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