scholarly journals Modeling and optimization of temperature in end milling operations

2019 ◽  
Vol 23 (6 Part A) ◽  
pp. 3651-3660
Author(s):  
Jelena Baralic ◽  
Nedeljko Ducic ◽  
Andjelija Mitrovic ◽  
Pavel Kovac ◽  
Miroslav Lucic
Keyword(s):  
End Milling ◽  
Cutting Speed ◽  
Infrared Camera ◽  
Milling Process ◽  
Optimization Techniques ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Machined Surface ◽  
Milling Operations

Milling is one of the most important and most complex cutting machining processes. During the milling process, the cross-section of the chip is variable. Also, all milling operations are interrupted processes. The cutting edge of the mill tooth periodically enters and exits from the contact with the workpiece, which leads to periodic heating and cooling during the machining. This periodic change of temperature significantly affects the process of tool wear and therefore the quality of the machined surface. This paper aims at modeling and optimizing the parameters of the machining process to achieve the minimum temperature. In order to perform optimization, it was necessary to perform temperature measurements for the various parameters of the machining process. An infrared camera was used for the temperature measurement. Then, based on the measured values, the mathematical modeling of the temperature was performed depending on the cutting speed, the feed rate and the depth of cut. This model is then optimized using two different optimization techniques.

scholarly journals Non-Invasive Estimation of Machining Parameters during End-Milling Operations Based on Acoustic Emission

Sensors ◽  
2020 ◽  
Vol 20 (18) ◽  
pp. 5326
Author(s):  
Andrés Sio-Sever ◽  
Erardo Leal-Muñoz ◽  
Juan Manuel Lopez-Navarro ◽  
Ricardo Alzugaray-Franz ◽  
Antonio Vizan-Idoipe ◽  
...  
Keyword(s):  
Acoustic Emission ◽  
End Milling ◽  
Low Cost ◽  
Milling Process ◽  
Machining Process ◽  
Measuring System ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Processes ◽  
Non Invasive

This work presents a non-invasive and low-cost alternative to traditional methods for measuring the performance of machining processes directly on existing machine tools. A prototype measuring system has been developed based on non-contact microphones, a custom designed signal conditioning board and signal processing techniques that take advantage of the underlying physics of the machining process. Experiments have been conducted to estimate the depth of cut during end-milling process by means of the measurement of the acoustic emission energy generated during operation. Moreover, the predicted values have been compared with well established methods based on cutting forces measured by dynamometers.

scholarly journals Optimization of CNC End Milling Process Parameters of Low-Carbon Mold Steel Using Response Surface Methodology and Grey Relational Analysis

2021 ◽  
Vol 2021 ◽  
pp. 1-11
Author(s):  
R. Suresh Kumar ◽  
S. Senthil Kumar ◽  
K. Murugan ◽  
B. Guruprasad ◽  
Sreekanth Manavalla ◽  
...  
Keyword(s):  
Regression Analysis ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Optimization Techniques ◽  
Machining Process ◽  
Depth Of Cut ◽  
Low Carbon ◽  
Box Behnken Design ◽  
Cnc End Milling

The manufacturing sectors are consistently striving to figure out ways to minimize the consumption of natural resources through rational utilization. This is achieved by a proper understanding of every minute influence of parameters on the entire process. Understanding the influencing parameters in determining the machining process efficacy is inevitable. Technological advancement has drastically improved the machining process through various means by providing better quality products with minimum machining cost and energy consumption. Specifically, the machining factors such as cutting speed, spindle speed, depth of cut, rate of feed, and coolant flow rate are found to be the governing factors in determining the economy of the machining process. This study is focused on improving the machining economy by enhancing the surface integrity and tool life with minimum resources. The study is carried out on low-carbon mold steel (UNS T51620) using Box–Behnken design and grey regression analysis. The optimized multiobjective solution for surface roughness (Ra), material removal rate (MRR), and power consumed (Pc) and tool life is determined and validated through the confirmatory run. The optimized set of parameters in Box–Behnken design and grey regression analysis with that of confirmatory runs shows a 10% deviation that proves the reliability of the optimization techniques employed.

scholarly journals Surface Integrity Investigation to Determine Rough Milling Effects for Assessment of Machining Allowance for Subsequent Finish Milling of Alloy 718

2021 ◽  
Vol 5 (2) ◽  
pp. 48
Author(s):  
Jonas Holmberg ◽  
Anders Wretland ◽  
Johan Berglund ◽  
Tomas Beno ◽  
Anton Milesic Karlsson
Keyword(s):  
Surface Integrity ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Milling Operations ◽  
Milling Operation ◽  
Machining Allowance ◽  
Rough Milling

The planned material volume to be removed from a blank to create the final shape of a part is commonly referred to as allowance. Determination of machining allowance is essential and has a great impact on productivity. The objective of the present work is to use a case study to investigate how a prior rough milling operation affects the finish machined surface and, after that, to use this knowledge to design a methodology for how to assess the machining allowance for subsequent milling operations based on residual stresses. Subsequent milling operations were performed to study the final surface integrity across a milled slot. This was done by rough ceramic milling followed by finish milling in seven subsequent steps. The results show that the up-, centre and down-milling induce different stresses and impact depths. Employing the developed methodology, the depth where the directional influence of the milling process diminishes has been shown to be a suitable minimum limit for the allowance. At this depth, the plastic flow causing severe deformation is not present anymore. It was shown that the centre of the milled slot has the deepest impact depth of 500 µm, up-milling caused an intermediate impact depth of 400 µm followed by down milling with an impact depth of 300 µm. With merged envelope profiles, it was shown that the effects from rough ceramic milling are gone after 3 finish milling passes, with a total depth of cut of 150 µm.

Performance assessment of energy efficient and eco-friendly turning of Nimonic C-263: A comparative study on MQL and cryogenic machining

2021 ◽  
pp. 095440542110619
Author(s):  
Prashant S Jadhav ◽  
Chinmaya P Mohanty
Keyword(s):  
Work Environment ◽  
Manufacturing Industry ◽  
Cutting Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cryogenic Machining ◽  
Machined Surface ◽  
Machining Strategies ◽  
The Impact

Nimonic C-263 is predominantly used in the manufacturing of heat susceptible intricate components in the gas turbine, aircraft, and automotive industries. Owing to its high strength, poor thermal conductivity, the superalloy is difficult to machine and causes rapid tool wear during conventional machining mode. Moreover, the unpleasant machining noise produced during machining severely disrupts the tool engineer’s concentration, thereby denying a precise and environment friendly machining operation. Hence, close dimensional accuracy, superior machined surface quality along with production economy, and pleasant work environment for the tool engineers is the need of an hour of the current manufacturing industry. To counter such issues, the present work attempts to compare and explore the machinability of two of the most popular machining strategies like minimum quantity lubrication (MQL) and cryogenic machining process during turning of Nimonic C-263 work piece in order to achieve an ideal machining environment. The machining characteristics are compared in terms of surface roughness (SR), power consumption (P), machining noise (S), nose wear (NW), and cutting forces (CF) to evaluate the impact of machining variables like cutting speed (Vc), feed (f), and depth of cut (ap) with a detailed parametric study and technical justification. Yet again, an investigation is conducted to compare both the machining strategies in terms of qualitative responses like chip morphology, total machining cost, and carbon emissions. The study revealed that cryogenic machining strategy is adequately proficient over MQL machining to deliver energy proficient and gratifying work environment for the tool engineers by reducing the cost of machining and improving their work efficiency.

Finite Element Analysis of a Frictionally Damped Slender Endmill

2012 ◽  
Author(s):  
Reza Madoliat ◽  
Sajad Hayati
Keyword(s):  
Finite Element ◽  
End Milling ◽  
Friction Stress ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Parameter Study ◽  
Bending Vibration ◽  
Element Analysis ◽  
Tool Axis

This paper primarily deals with suppression of chatter in end-milling process. Improving the damping is one way to achieve higher stability for machining process. For this purpose a damper is proposed that is composed of a core and a multi fingered hollow cylinder which are shrink fitted in each other and their combination is shrink fitted inside an axial hole along the tool axis. This structure causes a resisting friction stress during bending vibration. Using FEA-ANSYS the structure is simulated. Then a parameter study is carried out where the frequency response and the depth of cut are calculated and tabulated to obtain the most effective configuration. The optimal configuration of tool is fabricated and finite element results are validated using modal test. The results show a high improvement in performance of the tool with proposed damper. Good agreement between experiments and modeling is obtained.

Optimization of Process Parameters for Cutting Force for Aluminium 7010 in CNC End Milling Process

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
M. Kishanth ◽  
P. Rajkamal ◽  
D. Karthikeyan ◽  
K. Anand
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Optimization Of Process Parameters ◽  
Cnc End Milling ◽  
End Milling Process

In this paper CNC end milling process have been optimized in cutting force and surface roughness based on the three process parameters (i.e.) speed, feed rate and depth of cut. Since the end milling process is used for abrading the wear caused is very high, in order to reduce the wear caused by high cutting force and to decrease the surface roughness, the optimization is much needed for this process. Especially for materials like aluminium 7010, this kind of study is important for further improvement in machining process and also it will improve the stability of the machine.

Технологическое обеспечение качества поверхностного слоя стекловолоконных композитов при концевом фрезеровании

2020 ◽  
Vol 22 (4) ◽  
pp. 31-40
Author(s):  
Andrei Markov ◽  
◽  
Vyacheslav Nekrasov ◽  
Jian Su ◽  
Azhar Salman ◽  
...  
Keyword(s):  
Composite Materials ◽  
End Milling ◽  
Experimental Studies ◽  
Milling Process ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Scientific Publications ◽  
Experimental Assembly ◽  
Operation Results

Introduction. Today fiberglass is one of the most common composite materials. Therefore, its mechanical processing continues to be the subject of many studies. In many scientific publications, the influence of cutting modes and structural and geometric parameters of the tool on the roughness of the machined surface, cutting forces and wear of the cutting tool has been established. The purpose of this work is to study the effect of machining modes on delamination and roughness of fiberglass composites during end milling, as well as testing the hypothesis about the effect of torque on the delamination. The relevance of the study is due to the fact that delamination, along with roughness, has a significant impact on the quality of processing and subsequent assembly of the finished product. A criterion is proposed for assessing the magnitude of the delamination of composite materials during its machining. The results of experimental studies of the torque on the cutter, the relative coefficient of delamination and surface roughness from cutting conditions are presented. Methods: factorial experiment using an experimental assembly developed by the authors based on a piezoelectric torque sensor. The installation allows real-time recording of the change in torque during the milling process, depending on the modes of operation. Results and Discussion. A comparative analysis of the obtained dependences showed that the torque is directly related to delamination. To reduce the delamination, the depth of cut should be decreased, and in order to ensure the specified productivity, the feed and the rotational speed of the cutter should be increased. The presented results confirm the prospects of the developed approach aimed at machining new classes of composite materials.

Modeling & Analysis of End Milling Process Parameters Using Artificial Neural Networks

2014 ◽  
Vol 592-594 ◽  
pp. 2733-2737 ◽  
Author(s):  
G. Harinath Gowd ◽  
K. Divya Theja ◽  
Peyyala Rayudu ◽  
M. Venugopal Goud ◽  
M .Subba Roa
Keyword(s):  
Neural Networks ◽  
Artificial Neural Networks ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Artificial Neural ◽  
End Milling Process

For modeling and optimizing the process parameters of manufacturing problems in the present days, numerical and Artificial Neural Networks (ANN) methods are widely using. In manufacturing environments, main focus is given to the finding of Optimum machining parameters. Therefore the present research is aimed at finding the optimal process parameters for End milling process. The End milling process is a widely used machining process because it is used for the rough and finish machining of many features such as slots, pockets, peripheries and faces of components. The present work involves the estimation of optimal values of the process variables like, speed, feed and depth of cut, whereas the metal removal rate (MRR) and tool wear resistance were taken as the output .Experimental design is planned using DOE. Optimum machining parameters for End milling process were found out using ANN and compared to the experimental results. The obtained results provβed the ability of ANN method for End milling process modeling and optimization.

Chatter Investigation in Titanium Milling

2014 ◽  
Vol 1019 ◽  
pp. 318-324
Author(s):  
Jean Claude Fwamba ◽  
Lerato Crescelda Tshabalala ◽  
Cebo Philani Ntuli ◽  
Isaac Tlhabadira
Keyword(s):  
Feed Rate ◽  
End Milling ◽  
Processing Condition ◽  
Weight Ratio ◽  
Dimensional Accuracy ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Chatter Vibrations

<span><p align="LEFT"><span><span style="font-family: Times New Roman;" face="Times New Roman">Titanium and its alloys have been experiencing extensive development over the past few decades. They have found wide applications in the aerospace, biomedical and automotive industries owing to their good strength-to-weight ratio and high corrosion resistance. Machining performance is often limited by chatter vibrations at the tool-workpiece interface. Chatter is an abnormal tool behaviour which is one of the most critical problems in the machining process and must be avoided to improve the dimensional accuracy and surface quality of the finished product. This research aims at investigating chatter trends in the end milling process and to identify machine parameters that have effects on chatter during machining. The machine parameters investigated include axial feed rate, spindle revolute speed and depth of cut. In this research, experimental data was collected using sensors to analyze the existence of chatter vibrations on each processing condition. This research showed that the combination of the machine parameters, feed rate and spindle speed within certain proportions has an influence on machine vibrations during end milling and if not managed properly, may lead to chatter. </span></span></p> <p align="LEFT"></p>

scholarly journals OPTIMASI PARAMETER PERMESINAN TERHADAP WAKTU PROSES PADA PEMROGRAMAN CNC MILLING DENGAN BERBASIS CAD/CAM

2016 ◽  
Vol 6 (1) ◽  
Author(s):  
I G.N.K. Yudhyadi ◽  
Tri Rachmanto ◽  
Adnan Dedy Ramadan
Keyword(s):  
Cutting Speed ◽  
Operation Time ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine ◽  
Machining Parameter

Milling process is one of many machining processes for manufacturing component. The length of time in the process of milling machining is influenced by selection and design of machining parameters including cutting speed, feedrate and depth of cut. The purpose of this study to know the influence of cutting speed, feedrate and depth of cut as independent variables versus operation time at CNC milling process as dependent variables. Each independent variable consists of three level of factors; low, medium and high.Time machining process is measured from operation time simulation program, feed cut length and rapid traverse length. The results of statistically from software simulation MasterCam X Milling, then do comparison to CNC Milling machine.  The data from experiments was statistical analyzed by Anova and Regression methods by software minitab 16.Results show that the greater feedrate and depth of cut shorten the operation time of machinery, whereas cutting speed is not significant influence. Depth of cut has the most highly contribution with the value of 49.56%, followed by feedrate 43% and cutting speed 0.92%. Optimal time of machining process total is 71.92 minutes, with machining parameter on the condition cutting speed is 75360 mm/minutes, feedrate is 800 mm/minutes and depth of cut = 1 mm. Results of comparison time machining process in software Mastercam X milling with CNC Milling machine indicates there is difference not significant with the value of 0,35%.

Sign in / Sign up

Export Citation Format

Share Document