scholarly journals Research on Key Process Technology for Profile Electrolytic Finishing of Large Marine Propeller Impeller

2018 ◽  
Vol 25 (s2) ◽  
pp. 158-163
Author(s):  
Bi-Rong Ding ◽  
Yuan-long Chen ◽  
Ji Zhou ◽  
Pei-xuan Chen
Keyword(s):  
Manufacturing Industry ◽  
Simulation Software ◽  
Free Form ◽  
Surface Finishing ◽  
Motion Path ◽  
Machining Accuracy ◽  
Process Technology ◽  
Blade Machining ◽  
Cathode Structure ◽  
Free Form Surface

Abstract An electrolysis process method for free-form blade surface finishing is proposed for a free-form surface impeller, and a stepwise method is used to process the inter-blade channel of the overall impeller. The forming cathode is then used to finish the blade to meet the blade processing requirements. In the design, the forming cathode structure was improved by using motion simulation software, and the flow field simulation software was used to simulate and analyze the cathode flow channel. The cathode shape and the electrolyte flow rate between the electrodes meet the processing requirements. In the process of processing experiments, the motion path of the cathode was analyzed and optimized. The effect of the feed direction on the uneven distribution of the blade machining gap was reduced through optimization, and high-frequency pulse power processing was used to reduce the machining gap and improve the machining accuracy of the blade. The experimental results show that the process scheme is feasible and the precision of the processed impeller free-form surface is significantly improved. The material is a monolithic turbine disk of high-temperature alloys, and its large twisted blade processing has always been a problem in the manufacturing industry.

Tool Path Generation Method for High-Quality Machining of Free-Form Surfaces

2020 ◽  
Author(s):  
Yuki Takanashi ◽  
Hideki Aoyama
Keyword(s):  
Tool Path ◽  
High Accuracy ◽  
Tool Path Generation ◽  
Free Form ◽  
Machining Accuracy ◽  
Path Generation ◽  
High Quality ◽  
Nc Program ◽  
Free Form Surface ◽  
Free Form Surfaces

Abstract Machining data (NC program) is generated by a CAM system, which generates the tool path from the target shape as a plane approximation surface instead of a free-form surface. Owing to this plane approximation, machining accuracy is reduced. In this paper, we propose a method to process the shape with high accuracy by defining the areas where accuracy is not required as a plane approximation surface and defining the part where accuracy is required as free-form surfaces.

Theoretical Research on Polishing Free-Form Surface with Magnetic Abrasive Finishing

2008 ◽  
Vol 392-394 ◽  
pp. 404-408 ◽  
Author(s):  
Man Dong Zhang ◽  
Ming Lv ◽  
H.L. Chen
Keyword(s):  
Design Theory ◽  
Theoretical Research ◽  
Free Form ◽  
Machining Accuracy ◽  
Magnetic Pole ◽  
Computer Aided Geometric Design ◽  
Magnetic Abrasive Finishing ◽  
Abrasive Finishing ◽  
Free Form Surface ◽  
Free Form Surfaces

In the paper, polishing free-form surfaces of die are studied with magnetic abrasive finishing. The principle of magnetic abrasive finishing free-form surface, the design of magnetic pole, the composition and categories of magnetic abrasive are introduced. Through digitizing of free-form surface by using trimmed NURBS, based on residual roughness, machining accuracy and other parameters, the offset variable of free-form surface, which is the path of magnetic pole, is derived with the computer aided geometric design theory. These will provide theoretic foundation for the realization of finishing free-form surfaces of die automatically.

scholarly journals Increasing the Accuracy of Free-Form Surface Multiaxis Milling

Materials ◽  
2020 ◽  
Vol 14 (1) ◽  
pp. 25
Author(s):  
Marek Sadílek ◽  
Zdeněk Poruba ◽  
Lenka Čepová ◽  
Michal Šajgalík
Keyword(s):  
Computer Aided Design ◽  
Three Dimensional ◽  
Machining Process ◽  
Free Form ◽  
Machining Accuracy ◽  
Tool Axis ◽  
Computer Aided ◽  
Milled Surface ◽  
Inclination Angles ◽  
Free Form Surface

This contribution deals with the accuracy of machining during free-form surface milling using various technologies. The contribution analyzes the accuracy and surface roughness of machined experimental samples using 3-axis, 3 + 2-axis, and 5-axis milling. Experimentation is focusing on the tool axis inclination angle—it is the position of the tool axis relative to the workpiece. When comparing machining accuracy during 3-axis, 3 + 2-axis, and 5-axis milling the highest accuracy (deviation ranging from 0 to 17 μm) was achieved with 5-axis simultaneous milling (inclination angles βf = 10 to 15°, βn = 10 to 15°). This contribution is also enriched by comparing a CAD (Computer Aided Design) model with the prediction of milled surface errors in the CAM (Computer Aided Manufacturing) system. This allows us to determine the size of the deviations of the calculated surfaces before the machining process. This prediction is analyzed with real measured deviations on a shaped surface—using optical three-dimensional microscope Alicona Infinite Focus G5.

Study on the Rapid Progressive Die Design of Sheet Metal with Free Form Surface

2011 ◽  
Vol 328-330 ◽  
pp. 828-831 ◽  
Author(s):  
Xiao Da Li ◽  
Xiang Hui Zhan
Keyword(s):  
Sheet Metal ◽  
Simulation Software ◽  
Die Design ◽  
Free Form ◽  
Design Quality ◽  
Complex Part ◽  
Development Cycle ◽  
Free Form Surface ◽  
Key Steps ◽  
Forming Defects

The structure of progress die is generally more complex and need higher precision, so it needs a longer development cycle, especially for the progress die design of sheet metal with free form surface. In this paper, taking a relatively complex part with free form surface for instance, NX PDW which has highly automated design capabilities was applied to finish the mold design, and the key steps and methods of designing such parts with PDW was put forward. In the design process, the stamping simulation software Dynaform was also applied to simulate the key process to predict forming defects and assess the formability of sheet metal. The results show that the application of Dynaform and PDW can improve the design quality and efficiency greatly.

Development of a force controlled orbital polishing head for free form surface finishing

2010 ◽  
Vol 4 (2-3) ◽  
pp. 269-277 ◽  
Author(s):  
Christian Brecher ◽  
Roland Tuecks ◽  
Richard Zunke ◽  
Christian Wenzel
Keyword(s):  
Free Form ◽  
Surface Finishing ◽  
Free Form Surface

Sampling Based Assessment of the Free-Form Milling Strategies

2016 ◽  
Vol 686 ◽  
pp. 51-56 ◽  
Author(s):  
Jozef Beňo ◽  
Ildikó Maňková ◽  
Dagmar Draganovská ◽  
Peter Ižol
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Statistical Distribution ◽  
Free Form ◽  
Surface Finishing ◽  
Free Form Surface ◽  
Surface Decomposition ◽  
Free Form Surfaces ◽  
Paper Author ◽  
Sampling Approach

In this paper, author introduce common needs of increasing surface quality in tool making, a sort of products manufactured by free form milling technology. Principles of the free-form surface decomposition into measurable samples are presented and that is a method of combining CAD modeling with design of sampling objects. Sampling objects are classed both according to their measurability and applied milling strategy. Authors verify experimentally their sampling approach for three milling strategies applied in surface finishing operations while free-form surfaces are investigated in terms of their signed radii. Verification of proposed approach is based on statistical distribution of the measured surface roughness data.

Machining of Free-Form Surface Method and Implementation Research with Ball-End Cutter

2011 ◽  
Vol 697-698 ◽  
pp. 244-248
Author(s):  
Ke Hua Zhang ◽  
Li Min ◽  
Dong Hui Wen
Keyword(s):  
Tool Path ◽  
Computer Hardware ◽  
Free Form ◽  
Machining Accuracy ◽  
End Mill ◽  
Ball End Mill ◽  
Surface Machining ◽  
Free Form Surface ◽  
Tool Position ◽  
Five Axis

A new tool path generation method based on Z-buffer method is proposed for free-form surface machining by using ball-end cutters. Firstly, to avoid ball-end mill cutting the workpiece, we make the cutter shaft which is perpendicular to machining surface tilt angle θ, then determine the examining area and then judge there is or not a interference occurring between ball-end mill and examining area, if there is, then make a adjustment for cutter shaft. The discretized points within the examining area are efficiently read in and stored directly by the computer hardware; no extra searching and iterative methods are needed. Simulation results show that, comparing with the traditional algorithm, the tool-position calculation time is shorter, and the phenomenon of workpiece squeezed and scratched is less in this algorithm. It meets the basic needs of five axis machining accuracy. Finally we make a practical machining experiment for cutter location generated.

The Effect of Normal Curvature of the Free Surface on the Cutting Width

2011 ◽  
Vol 328-330 ◽  
pp. 332-335
Author(s):  
Ming Hai Wang ◽  
Xiao Peng Li ◽  
Lei Sun ◽  
Yue Sun
Keyword(s):  
Free Surface ◽  
Cutting Tools ◽  
Surface Curvature ◽  
Normal Curvature ◽  
Free Form ◽  
Machining Accuracy ◽  
Machined Surface ◽  
Surface Machining ◽  
Free Form Surface

This paper analyzes the influence of processing surface curvature of the free surface to the cutting width to improve the cutting width of free surface. The results show that this analysis is feasible to improve the process if the machining accuracy allows. It shows that the curvature of the machined surface and the curvature of the cutting tools have a great impact on the cutting width if they are matched reasonable. Therefore, analyzing the curvature of the surface of the surface of free-form surface machining can improve the cutting width effectively.

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