scholarly journals Influence of stiffness of the mechanical part of the drive and cutting parameters on the shaping elastic deformation control

2021 ◽  
Vol 21 (2) ◽  
pp. 154-162
Author(s):  
V. L. Zakovorotny ◽  
V. Е. Gvindjiliya ◽  
А. А. Zakalyuzhny
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Tool Path ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Return Flow ◽  
Elastic Deformations ◽  
Mechanical Part ◽  
Feed Drive ◽  
The Law

Introduction. One of the ways to improve the accuracy of manufacturing parts by cutting is related to the control of elastic deformations of the tool and the workpiece. This is particularly true for slender parts, whose stiffness law along the tool path is given. In this case, the control parameter, as a rule, is the return flow rate, which affects the cutting forces, whose change causes variations in elastic deformations. To provide the specified accuracy of the diameter, it is required to coordinate the controlled trajectory of the feed drive speed with the feed rate and a priori given law of change in the stiffness of the workpiece or the law of variation of the cutting process parameters. To do this, it is required to determine the law of converting the engine speed into the feed rate, and, ultimately, into elastic deformations. This law depends on the stiffness of the mechanical part of the feed drive and the changing parameters of the cutting process.Materials and Methods. The paper presents mathematical modeling and, on its basis, analysis of the conversion of the feed rate into cutting forces, taking into account the final stiffness value of the mechanical part of the drive and the evolutionary parameters of the cutting process.  Results. It is shown that, starting from a certain critical value, the law of converting the feed rate into cutting forces becomes fundamentally dependent on the stiffness of the mechanical part of the drive. At the same time, there is an increase in time for setting a new force value when the feed rate varies, which affects the accuracy of providing forces that are consistent with the stiffness law of the part. The paper presents algorithms for calculating elastic deformations for a given stiffness law, as well as algorithms for calculating the trajectory of the feed rate at which the deformations remain constant. It is shown that the law of conversion is also affected by variations in the cutting parameters. Discussion and Conclusion. The frequency and time characteristics of the conversion are discussed. A conclusion is made about the accuracy of the diameter formed through cutting, depending on the stiffness of the mechanical part of the feed drive and on some parameters of the cutting process. 

Characterizing the Effect of Cutting Condition, Tool Path, and Heat Treatment on Cutting Forces of Selective Laser Melting Spherical Component in Five-Axis Milling

2018 ◽  
Vol 140 (5) ◽  
Author(s):  
Amir Mahyar Khorasani ◽  
Ian Gibson ◽  
Moshe Goldberg ◽  
Guy Littlefair
Keyword(s):  
Heat Treatment ◽  
Production Process ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
Tool Path ◽  
Annealing Temperature ◽  
Spindle Speed ◽  
Cutting Condition ◽  
Scallop Height

Additive manufacturing (AM), partly due to its compatibility with computer-aided design (CAD) and fabrication of intricate shapes, is an emerging production process. Postprocessing, such as machining, is particularly necessary for metal AM due to the lack of surface quality for as-built parts being a problem when using as a production process. In this paper, a predictive model for cutting forces has been developed by using artificial neural networks (ANNs). The effect of tool path and cutting condition, including cutting speed, feed rate, machining allowance, and scallop height, on the generated force during machining of spherical components such as prosthetic acetabular shell was investigated. Also, different annealing processes like stress relieving, mill annealing and β annealing have been carried out on the samples to better understand the effect of brittleness, strength, and hardness on machining. The results of this study showed that ANN can accurately apply to model cutting force when using ball nose cutters. Scallop height has the highest impact on cutting forces followed by spindle speed, finishing allowance, heat treatment/annealing temperature, tool path, and feed rate. The results illustrate that using linear tool path and increasing annealing temperature can result in lower cutting force. Higher cutting force was observed with greater scallop height and feed rate while for higher finishing allowance, cutting forces decreased. For spindle speed, the trend of cutting force was increasing up to a critical point and then decreasing due to thermal softening.

Predictive Modeling and Optimization of Cutting Forces Through RSM and Taguchi Techniques in the Turning of ASTM B574 (Hastelloy C-22)

2018 ◽  
pp. 398-417
Author(s):  
İsmail Kırbaş ◽  
Musa Peker ◽  
Gültekin Basmacı ◽  
Mustafa Ay
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Rake Angle ◽  
Orthogonal Experimental Design ◽  
Depth Of Cut ◽  
Effective Parameters ◽  
Factors Affecting ◽  
The Impact

In this chapter, the impact of cutting parameters (depth of cut, cutting speed, feed, flow, rake angle, lead angle) on cutting forces in the turning process with regard to ASTM B574 (Hastelloy C-22) material has been investigated. Variance analysis has been applied in order to determine the factors affecting the cutting forces. The optimization of the parameters affecting the surface roughness has been obtained using response surface methodology (RSM) based on the Taguchi orthogonal experimental design. The accuracy of the developed models required for the estimation of the force values (Fx, Fy, Fz) is quite successful. In this study, where the R2 value has been used as the criterion/measure, accuracy values of 93.35%, 95.03%, and 95.09% have been achieved for Fx, Fy, and Fz, respectively. As a result of the ANOVA analysis, the most effective parameters for Fx at a 95% confidence interval are depth of cut, feed rate, flow, and rake angle. The most effective parameter for Fy is depth of cut, while the most effective parameters for Fz are depth of cut, feed rate, and flow, respectively.

scholarly journals Online Tool Wear Monitoring by the Analysis of Cutting Forces in Transient State for Dry Machining of Ti6Al4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 1014 ◽  
Author(s):  
Sánchez Hernández ◽  
Trujillo Vilches ◽  
Bermudo Gamboa ◽  
Sevilla Hurtado
Keyword(s):  
Tool Wear ◽  
Feed Rate ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Transient State ◽  
Cutting Parameters ◽  
Dry Machining ◽  
Crater Wear ◽  
Force Amplitude

In this work, the analysis of the cutting speed and feed rate influence on tool wear and cutting forces in Ti6Al4V alloy dry machining is presented. The study has been focused on the machining in a transient state. The tool wear mechanisms, tool wear intensity and cutting forces evolution have been analyzed as a function of the cutting parameters. Experimental results show that the main cutting force amplitude exhibits a general trend to increase with both cutting parameters. Crater wear was more evident at high cutting speeds, whereas flank wear was present on the whole interval of the cutting parameters analyzed. Furthermore, the cutting speed shows a slightly higher influence on crater wear and the feed rate shows a higher influence on flank wear. Finally, several experimental parametric models have been obtained. These models allow predicting the evolution of crater and flank tool wear, as well as the cutting forces, as a function of the cutting parameters. Additionally, a model that allows monitoring the tool wear on the machining transient state as a function of the main cutting force amplitude has been developed.

On Cutting Process of Stainless Steel Fiber with Complex Surface Morphology

2010 ◽  
Vol 139-141 ◽  
pp. 634-638 ◽  
Author(s):  
Biao Tang ◽  
Yong Tang ◽  
Rui Zhou ◽  
Zhen Ping Wan
Keyword(s):  
Stainless Steel ◽  
Surface Morphology ◽  
Feed Rate ◽  
Steel Fiber ◽  
Complex Surface ◽  
Cutting Parameters ◽  
Steel Fibers ◽  
Cutting Process ◽  
Forming Process ◽  
Stainless Steel Fiber

To meet the increasing application requirements of stainless steel fibers with rough surface morphology, a self-made multi-tooth tool which can bifurcate chip during the cutting process was utilized to manufacture stainless steel fibers. The novel cutting method can achieve efficient processing of continuous stainless steel fibers with complex surface morphology. The influence of cutting parameters (back engagement ap and feed rate f ) on forming process of fibers’ surface morphology was studied. The cutting experiments were carried out under the condition of selected tool and fixed workpiece rotating speed. The results show that: the surface morphology of stainless steel fiber is simultaneously effected by ap,and feed rate f .Between them, ap has more significant effect on it. In order to obtain stainless steel continuous fibers with coarse surface morphology, the optimum cutting parameters were recommended as follows: ap∈(0.1-0.2) mm, f ∈(0.1 -0.17) mm/r.

scholarly journals METHOD FOR CALCULATING CUTTING FORCES BY MODELING CAD WITH A SYSTEM OF GEOMETRIC CUTTING PARAMETERS WITH RADIAL MILLS

2021 ◽  
pp. 50-57
Author(s):  
Alexander Leshchenko
Keyword(s):  
Cutting Forces ◽  
Tool Path ◽  
Cutting Parameters ◽  
Cutting Edge ◽  
Software Module ◽  
Power Characteristics ◽  
Cad System ◽  
Shaping Process ◽  
End Mills ◽  
Processing Zone

The accuracy of processing surfaces of a complex profile largely depends on the selected processing strategy, which will allow creating the same, within certain limits, power characteristics of the shaping process at the intervals of the programmed tool path. In this case, it becomes possible to include tuning modules in programs for CNC machines that form vector values of corrections in certain areas, as reactors for elastic deformations of the cutting process. Therefore, it is especially important to know the modulus and direction of the resulting cutting force vector, which does not necessarily coincide with the feed direction. The purpose of this work is to build a method for calculating cutting forces by modeling the geometric parameters of a cut with a CAD system, a cutter with a nonlinear generatrix. Solid modeling of the process is based on the Boolean operations of "intersection" and "subtraction" of 3D objects: the teeth of a radius cutter with a helical cutting edge and a workpiece "moving" at a feed rate. The tool for the implementation of this method is a software module created on the basis of API functions, the input data for which are: a 3D tool and a workpiece, the equation of the trajectory of its movement and the parameters of the infeed movement. Targeting API properties, the application makes it possible to simulate various trajectories, helical or trochoidal, when machining complex surfaces. In the future, it is possible to take into account the plastic deformation processes in the chip formation zone in the model by connecting external modules. In the course of the conducted research on milling with radial end mills with a helical cutting edge, when two or more teeth are within the arc of contact, it was determined by 3D modeling how much thickness and width the layer cuts off each of the teeth during the feed per revolution. Consequently, in the process of shaping, normal and tangential cutting forces, which are different in direction and modulus, are present as a function of the angle of rotation of the cutter. Therefore, the concept of "circumferential force on the cutter", accepted in the theory of cutting, as a certain constant component of the process, can introduce an error when considering the causes of the excitation mechanism of vibrations of different nature that arise in the processing zone.

scholarly journals An Investigation into the Effect of Electro-Contact Heating in the Machining of Low-Rigidity Thin-Walled Micro-Machine Parts

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4427
Author(s):  
Antoni Świć ◽  
Arkadiusz Gola ◽  
Olga Orynycz ◽  
Karol Tucki
Keyword(s):  
Control System ◽  
Feed Rate ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Contact Heating ◽  
Thin Walled ◽  
Micro Machine

Low-rigidity thin-walled parts are components of many machines and devices, including high precision electric micro-machines used in control and tracking systems. Unfortunately, traditional machining methods used for machining such types of parts cause a significant reduction in efficiency and in many cases do not allow obtaining the required accuracy parameters. Moreover, they also fail to meet modern automation requirements and are uneconomical and inefficient. Therefore, the aim of provided studies was to investigate the dependency of cutting forces on cutting parameters and flank wear, as well as changes in cutting forces induced by changes in heating current density and machining parameters during the turning of thin-walled parts. The tests were carried out on a specially designed and constructed turning test stand for measuring cutting forces and temperature at specific cutting speed, feed rate, and depth of cut values. As part of the experiments, the effect of cutting parameters and flank wear on cutting forces, and the effect of heating current density and turning parameters on changes in cutting forces were analyzed. Moreover, the effect of cutting parameters (depth of cut, feed rate, and cutting speed) on temperature has been determined. Additionally, a system for controlling electro-contact heating and investigated the relationship between changes in cutting forces and machining time in the operations of turning micro-machine casings with and without the use of the control system was developed. The obtained results show that the application of an electro-contact heating control system allows to machine conical parts and semi-finished products at lower cutting forces and it leads to an increase in the deformation of the thin-walled casings caused by runout of the workpiece.

Cutting Process Simulation in Micro Dimple Machining

2019 ◽  
Author(s):  
Takashi Matsumura ◽  
Yuji Musha
Keyword(s):  
Cutting Forces ◽  
Rotation Axis ◽  
Flow Direction ◽  
Mechanistic Model ◽  
Cutting Parameters ◽  
Process Models ◽  
Cutting Process ◽  
High Rate ◽  
Force Model ◽  
Micro Dimple

Abstract The paper discusses micro dimple millings with inclined ball end mills. Cutting process models are presented to control the dimple shapes and predict the cutting forces. In micro dimple milling, the cutter rotation axis is inclined to have the non-cutting time, during which the cutting edges don’t remove the material in a rotation of cutter. The end mill is fed at a high rate so that the machining areas removed by the cutting edges are not overlapped each other. The shapes and the alignment of the dimples are simulated for the cutting parameters in the mechanistic model. Then, the cutting forces are predicted for high machining accuracies. The cutting experiments were conducted to verify the micro dimple machining. The dimple shape model is validated in comparison between the simulated and the actual dimple shapes. The cutting forces are simulated to compare the measured ones. The force model works well to predict the cutting forces with the chip flow direction during a rotation of the cutter.

Off-Line Feed Rate Scheduling Using Virtual CNC

2007 ◽  
Vol 10-12 ◽  
pp. 451-455
Author(s):  
J. Wu ◽  
Ying Xue Yao ◽  
J.G. Li
Keyword(s):  
Feed Rate ◽  
Cutting Parameters ◽  
Cnc Machining ◽  
Machining Time ◽  
Cutting Power ◽  
Feed Drive ◽  
Nc Program ◽  
Increase Productivity ◽  
Rate Scheduling ◽  
Drive Systems

Maximally utilizing the capabilities offered by the feed drive systems in the CNC machining can both increase productivity and improve product quality. In this study, a framework of off-line feed rate scheduling was presented and a turning machining simulation and feed rate optimal system was developed. The system take advantage of virtual machining acquires cutting parameters and predicts cutting forces and cutting power. Constant cutting power was used as an objective to optimize feed rate, the feed rate in NC program was re-scheduled. The experiment results show that machining time is reduced and machining stability is improved by using the optimized NC program.

Minimum Time Trajectory Planning Along Specified Tool Path With Consideration of Cutting Force Constraint and Feed Drive Dynamics

Manufacturing ◽  
2002 ◽  
Author(s):  
Nejah Tounsi ◽  
Trevor E. Bailey ◽  
Mohamed A. Elbestawi
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Tool Path ◽  
End Milling ◽  
Low Frequency ◽  
Minimum Time ◽  
Force Model ◽  
Modeling And Analysis ◽  
Feed Drive ◽  
Drive Dynamics

This paper proposes an Optimized Feed Scheduling Strategy (OFSS). This strategy integrates the feed drive dynamics with the minimum-time trajectory planing to achieve the desired feed rate at the appropriate tool position along specified tool path. It optimizes the use of the feed drive capabilities and provides good tracking of the cutting geometry variations. The feed scheduling is applied to maintain near-constant cutting force magnitude. An integrated geometric and mechanistic force model is used to estimate the in-cut geometry and the cutting force. A methodology based on time series modeling and analysis is proposed to identify the low frequency feed drive dynamics. The resulting model is applied as an acceleration/deceleration processor (Acc/Dec) to relate the actual feed rate to the commanded feed rate specified in the G-Code file. The effectiveness of the OFSS is analyzed using ball end milling operations. Its performance in terms of productivity and machining safety is assessed based on comparison with other feed scheduling techniques where the trajectory planing does not consider the feed drive dynamics.

scholarly journals Experimental Investigation and Statistical Evaluation of Optimized Cutting Process Parameters and Cutting Conditions to Minimize Cutting Forces and Shape Deviations in Al6026-T9

Materials ◽  
2020 ◽  
Vol 13 (19) ◽  
pp. 4327 ◽  
Author(s):  
Muhammad Abas ◽  
Bashir Salah ◽  
Qazi Salman Khalid ◽  
Iftikhar Hussain ◽  
Abdur Rehman Babar ◽  
...  
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
Virgin Olive Oil ◽  
Cutting Parameters ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Signal To Noise ◽  
Shape Deviations ◽  
Measuring Machine ◽  
Tungsten Carbide Tool

Precise, economical and sustainable cutting operations are highly desirable in the advanced manufacturing environment. For this aim, the present study investigated the influence of cutting parameters (i.e., the cutting speed (c), feed rate (f), depth of cut (d) and positive rake angle (p)) and sustainable cutting conditions (dry and minimum quantity lubricant (MQL)) on cutting forces (i.e., feed force (Ff), tangential forces (Ft), radial force (Fr) and resultant cutting forces (Fc) and shape deviations (i.e., circularity and cylindricity) of a 6026-T9 aluminum alloy. The type of lubricant and insert used are virgin olive oil and uncoated tungsten carbide tool. Turning experiments were performed on a TAKISAWA TC-1 CNC lathe machine and cutting forces were measured with the help of a Kistler 9257B dynamometer. Shape deviations were evaluated by means of a Tesa Micro-Hite 3D DCC 474 coordinate measuring machine (CMM). Experimental runs were planned based on Taguchi mixture orthogonal array design L16. Analysis of variance (ANOVA) was performed to study the statistical significance of cutting parameters. Taguchi based signal to noise (S/N) ratios are applied for optimization of single response, while for optimization of multiple responses Taguchi based signal to noise (S/N) ratios coupled with multi-objective optimization on the basis of ratio analysis (MOORA) and criteria importance through inter-criteria correlation (CRITIC) are employed. ANOVA results revealed that feed rate, followed by a depth of cut, are the most influencing and contributing factors for all components of cutting forces (Ff, Ft, Fr, and Fc) and shape deviations (circularity and cylindricity). The optimized cutting parameters obtained for multi responses are c = 600 m/min, f = 0.1 mm/rev, d = 1 mm and p = 25°, while for cutting conditions, MQL is optimal.

Sign in / Sign up

Export Citation Format

Share Document