scholarly journals Study on Deformation and Compensation for Micromilled Thin Walls With High Aspect Ratios

2021 ◽  
Author(s):  
Yang Li ◽  
Xiang Cheng ◽  
Siying Ling ◽  
Guangming Zheng ◽  
Lei He
Keyword(s):  
Cutting Force ◽  
Force Measurement ◽  
Dimensional Accuracy ◽  
Cutting Process ◽  
Machining Process ◽  
Thin Wall ◽  
Cutting Parameter ◽  
Thin Walls ◽  
Aspect Ratios ◽  
Wall Deformation

Abstract In order to further improve the dimensional accuracy of micromilled thin walls with high aspect ratios, the machining process should be actively controlled. An active cutting force measurement and cutting parameter compensation device is developed to realize the real-time measurement of radial cutting forces and compensation of radial cutting parameters in thin wall cutting process. Firstly, based on the cantilever beam deformation theory, a mathematical model is established to calculate the deformation and cutting force of thin walls. By measuring the cutting force, the thin wall deformation in the cutting process could be estimated. Then, the obtained incremental thin wall deformation is to be compared with the compensation threshold, which is set at 0.5 μm. If the value of the incremental deformation is less than 0.5 μm, compensation will not be processed. Otherwise, the incremental deformation is used as the compensation value for iterative compensation, until the incremental deformation of the thin wall is less than 0.5 μm. At last, a contrast experiment is carried out. The experimental results show that the introduced device and method are feasible. Machining quality of the thin wall has been obviously improved in dimension precision after the cutting parameter compensations.

Numerical Simulation of Metal Cutting Process Based on ANSYS/LS-DYNA

2015 ◽  
Vol 727-728 ◽  
pp. 335-338 ◽  
Author(s):  
Song Jie Yu ◽  
Di Di Wang ◽  
Xin Chen
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Plastic Material ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Machining Process ◽  
Linear Deformation ◽  
Deformation Problem ◽  
Non Linear ◽  
Elastic Plastic Material

Cutting process is a typical non-linear deformation problem, which involves material non-linear, geometry non-linear and the state non-linear problem. Based on the elastic-plastic material deformation theory, this theme established a strain hardening model. Build the simulation model of two-dimensional orthogonal cutting process of workpiece and tool by the finite element method (FEM), and simulate the changes of cutting force and the process of chip formation in the machining process, and analyzed the cutting force, the situation of chip deformation. The method is more efficient and effective than the traditional one, and provides a new way for metal cutting theory, research of material cutting performance and cutting tool product development.

scholarly journals Design, development, calibration, and testing of indigenously developed strain gauge based dynamometer for cutting force measurement in the milling process

2020 ◽  
Vol 14 (2) ◽  
pp. 6594-6609 ◽  
Author(s):  
T. Mohanraj ◽  
S. Shankar ◽  
R. Rajasekar ◽  
M.S. Uddin
Keyword(s):  
Cutting Force ◽  
Dynamic Characteristics ◽  
Strain Gauge ◽  
Force Measurement ◽  
Machining Process ◽  
Series Data ◽  
Design Development ◽  
Element Analysis ◽  
Cross Sensitivity ◽  
Static And Dynamic Characteristics

In this work, a milling dynamometer based on strain gauge with an octagonal and square ring was designed and tested. Strain gauges were attached with the mechanical rings to detect the deformation, during the machining process. Wheatstone bridge circuit was equipped with gauges to acquire the strain as voltage owing to the deformation of mechanical rings when machining takes place. The finite element analysis (FEA) was used to identify the location of maximum deformation and stress. The direction of rings and location of gauges were decided to increase the sensitivity and decrease the cross-sensitivity. Then, the cutting force was acquired through NI 6221 M series data acquisition (DAQ) card. The dynamometer had undergone a cycle of tests to verify its static and dynamic characteristics. The metrological characterization was performed according to the calibration procedure based on ISO 376 – 2011 standard. The cutting force was measured with both the dynamometers through milling experiments based on Taguchi’s L9 orthogonal array and the results were recorded. The measured cutting force varied from 300 N to 550 N. The obtained results depicted that low-cost milling dynamometer was reliable to measure the three component machining force. Overall, the square ring based dynamometer provides the better static and dynamic characteristics in terms of linearity, cross-sensitivity (4%), uncertainty (0.054%), and natural frequency (362.41 rev/s).

scholarly journals Cutting Forces Measurement for Milling Process by Using Working Tables with Integrated PVDF Thin-Film Sensors

Sensors ◽  
2018 ◽  
Vol 18 (11) ◽  
pp. 4031 ◽  
Author(s):  
Ming Luo ◽  
Zenghui Chong ◽  
Dongsheng Liu
Keyword(s):  
Thin Film ◽  
Cutting Force ◽  
Cutting Forces ◽  
Polyvinylidene Fluoride ◽  
Force Measurement ◽  
Milling Process ◽  
Machining Process ◽  
Signal Spectrum ◽  
Milling Force ◽  
Thin Film Sensors

In the milling process, cutting forces contain key information about the machining process status in terms of workpiece quality and tool condition. On-line cutting force measurement is key for machining condition monitoring and machined surface quality assurance. This paper presents a novel instrumented working table with integrated polyvinylidene fluoride (PVDF) thin-film sensors, thus enabling the dynamic milling force measurement with compact structures. To achieve this, PVDF thin-film sensors are integrated into the working table to sense forces in different directions and the dedicated cutting force decoupling model is derived. A prototype instrumented working table is developed and validated. The validation demonstrates that profiles of the forces measured from the developed instrumented working table prototype and the dynamometer match well. Furthermore, the milling experiment results convey that the instrumented working table prototype could also identify the tool runout due to tool manufacturing or assembly errors, and the force signal spectrum analysis indicates that the developed working table can capture the tool passing frequency correctly, therefore, is suitable for the milling force measurement.

scholarly journals The Effect of Cutting Fluids and Cutting Speeds to The Vibrations of Milling CNC Machine

2017 ◽  
Vol 16 (2) ◽  
Author(s):  
A Muhammad Fuad Nur Rochim ◽  
Indri Yaningsih ◽  
Heru Sukanto
Keyword(s):  
Cutting Force ◽  
External Force ◽  
Face Milling ◽  
Cutting Process ◽  
Machining Process ◽  
Cutting Fluids ◽  
Cnc Machine ◽  
Accelerometer Sensor ◽  
Slot Milling ◽  
Cutting Speeds

Vibration that occur in machining process is forced vibration. This vibration caused by external force excitation. External force that cause vibration in machining process is cutting force. This research was aims to determine the effect of cutting fluids and cutting speeds to vibration in milling process. The specimens were made using a cutting process type face milling, profile milling, pocket milling, and slot milling. Cutting speeds was variated at 62.83 m/min; 110 m/min; 157.14 m/min; 188.5 m/min. Vibration testing was done using the accelerometer sensor. Vibration response taken is the amplitude. The results show any type of cutting process has a different amplitude. Face milling has the smallest amplitude while slot milling has the biggest one. At cutting speeds parameter, the faster of cutting speeds the smaller of the amplitude. The use of cutting fluids can reduce the friction value between cutting tool and workpiece so that the cutting force will decrease. The use of cutting fluids causing the smaller the cutting force. The increase of the cutting force will cause greater vibration

scholarly journals Studying of Technological Characteristics in Cutting Zone by Multifunction Measuring System

2012 ◽  
Vol 9 (2) ◽  
pp. 38-42
Author(s):  
Michal Šajgalík ◽  
Andrej Czán ◽  
Marek Szigety ◽  
Róbert Bobrovský
Keyword(s):  
Temperature Field ◽  
Cutting Force ◽  
Cutting Process ◽  
Machining Process ◽  
Measuring System ◽  
Technological Characteristics ◽  
Comprehensive Information ◽  
Cutting Zone

Abstract In this manuscript are described and evaluated processes in cutting zone during machining process by turning based on the results of the multifunction measuring system. This system consists of three different measuring units, which allow to measure and monitor processes in the cutting zone, such as size of components of cutting force, temperature field and its evolution during the cutting process, etc. The results as the data from each unit of multifunction measuring system provide detailed and comprehensive information about processes in cutting zone during the machining and they help to better knowledge of processes in cutting zone during the machining.

Chip Formation of Highly Efficient Cutting Titanium Alloy Membrane Disk

2010 ◽  
Vol 33 ◽  
pp. 549-554
Author(s):  
Shu Cai Yang ◽  
Min Li Zheng ◽  
Yi Hang Fan
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Chip Formation ◽  
Fem Analysis ◽  
Cutting Conditions ◽  
Machining Process ◽  
Thin Wall ◽  
Variable Cross ◽  
Serrated Chip ◽  
Membrane Disk

Titanium alloy membrane disk is a typical part in aerial engine and it belongs to variable cross-section thin-wall part, which is apt to change its nature and difficult to machine. Serrated chip is prone to create in the machining process. A periodic serrated chip will cause high frequency undulation of the cutting force, and further leads to the cutting tool wear and affect the surface’s integrity. Based on the turning of titanium membrane disk, this paper used metallographic microscope and SEM to observe the morphology and micro shape of the chip, and analyzed the influence of cutting conditions on chip formation and the reason for serrated chip. Finally, a FEM analysis on the chip formation process is completed. Analysis results show that under all the set cutting conditions the serrated chip was formed in the machining process. The shearing slippage and fracture caused by dislocation movement can better explain the formation mechanism of serrated chip. The feed rate has great effect on the chip formation and the forming frequency of serrated chip. The FEM analysis results primly consistent with the experiment results, which can accurately forecast the cutting force, the distribution of temperature and the surface quality.

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.

scholarly journals Process Parameters Optimization of Thin-Wall Machining for Wire Arc Additive Manufactured Parts

2020 ◽  
Vol 10 (21) ◽  
pp. 7575 ◽  
Author(s):  
Niccolò Grossi ◽  
Antonio Scippa ◽  
Giuseppe Venturini ◽  
Gianni Campatelli
Keyword(s):  
Parameters Optimization ◽  
Machining Process ◽  
Test Case ◽  
Thin Wall ◽  
Machining Parameters ◽  
Thin Walls ◽  
Software Updating ◽  
Cutting Parameter Optimization ◽  
Set Up ◽  
Monolithic Components

Additive manufacturing (AM) is an arising production process due to the possibility to produce monolithic components with complex shapes with one single process and without the need for special tooling. AM-produced parts still often require a machining phase, since their surface finish is not compliant with the strict requirements of the most advanced markets, such as aerospace, energy, and defense. Since reduced weight is a key requirement for these parts, they feature thin walls and webs, usually characterized by low stiffness, requiring the usage of low productivity machining parameters. The idea of this paper is to set up an approach which is able to predict the dynamics of a thin-walled part produced using AM. The knowledge of the workpiece dynamics evolution throughout the machining process can be used to carry out cutting parameter optimization with different objectives (e.g., chatter avoidance, force vibrations reduction). The developed approach exploits finite element (FE) analysis to predict the workpiece dynamics during the machining process, updating its changing geometry. The developed solution can automatically optimize the toolpath for the machining operation, generated by any Computer Aided Manufacturing (CAM) software updating spindle speed in accordance with the selected optimization strategies. The developed approach was tested using as a test case an airfoil.

scholarly journals On-Line Compensation for Micromilling of High-Aspect-Ratio Straight Thin Walls

Micromachines ◽  
2021 ◽  
Vol 12 (6) ◽  
pp. 603
Author(s):  
Yang Li ◽  
Xiang Cheng ◽  
Siying Ling ◽  
Guangming Zheng
Keyword(s):  
Aspect Ratio ◽  
Cutting Parameters ◽  
Thin Wall ◽  
Dimensional Error ◽  
Machining Quality ◽  
Thin Walls ◽  
Wall Deformation ◽  
On Line ◽  
Dimensional Errors ◽  
Parameter Compensation

In order to improve the machining quality and reduce the dimensional errors of micro high-aspect-ratio straight thin walls, the on-line cutting parameter compensation device has been introduced and corresponding micromilling processes have been investigated. Layered milling strategies for the micromilling of thin walls have been modeled and simulated for thin walls with different thicknesses based on the finite element method. The radial cutting parameters compensation method is adopted to compensate the thin wall deformation by raising the radial cutting parameters since the thin wall deformation make the actual radial cutting parameters smaller than nominal ones. The experimental results show that the dimensional errors of the thin wall have been significantly reduced after the radial cutting parameter compensation. The average relative dimensional error is reduced from 6.9% to 2.0%. Moreover, the fabricated thin walls keep good shape formation. The reduction of the thin wall dimensional error shows that the simulation results are reliable, which has important guiding significance for the improvement of thin wall machining quality, especially the improvement of dimensional accuracy. The experimental results show that the developed device and the machining strategy can effectively improve the micromilling quality of thin walls.

A Stress Distribution of Thin Rectangular Steel Wall Under a Uniform Compression

2020 ◽  
Vol 20 (03) ◽  
pp. 2050037 ◽  
Author(s):  
Yang Lv ◽  
Zheng Zhao ◽  
Jia-Qi Lv ◽  
Nawawi Chouw ◽  
Zhong-Xian Li
Keyword(s):  
Stress Distribution ◽  
Element Model ◽  
Shear Capacity ◽  
Thin Wall ◽  
Uniform Compression ◽  
Thin Walls ◽  
Buckling Stress ◽  
Aspect Ratios ◽  
Segment Distribution ◽  
Earthquake Load

The stress distribution of a steel wall is important in the determination of its shear capacity, e.g. under a wind load or an earthquake load. Since the wall has also to simultaneously carry the gravity load, the influence of this uniform vertical load on the stress distribution is relevant. For a simple-supported thick and square wall, a stress distribution in a cosine form was adequate. However, for an extremely thin wall, a cosine distribution is no longer valid, especially in the post-buckling condition. In this work a three-segment distribution is proposed, i.e. at both edge segments a cosine distribution from edge stress to buckling stress and in the middle segment a constant distribution of buckling stress. To evaluate the proposed distribution, a finite element model using the software ANSYS/LS-DYNA is developed. This model has been verified using the results obtained from own experiments and works done by others. The results show that the proposed stress distribution is able to describe the behavior of thin walls for different aspect ratios and slendernesses. The cosine distribution and the effective width model are also discussed.

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