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.

Research on Finite Element Simulation and Parameters Optimization of Milling 7050-T7451 Aluminum Alloy Thin-walled Parts

2020 ◽  
Vol 14 ◽  
Author(s):  
Song Yang ◽  
Tie Yin ◽  
Feiyue Wang
Keyword(s):  
Aluminum Alloy ◽  
Complex Structure ◽  
Parameters Optimization ◽  
Thin Wall ◽  
Machining Parameters ◽  
Milling Parameters ◽  
Machining Deformation ◽  
Milling Temperature ◽  
Thin Walled ◽  
Milling Forces

Background: Thin-walled parts of aluminum alloy are easy to occur machining deformation duo to the characteristics of thin wall, low rigidity, and complex structure. Objective: To reduce and control the machining deformation, it is necessary to select reasonable machining parameters. Method: The influence of milling parameters on the milling forces, milling temperature, and machining deformation was analyzed through the established model based on ABAQUS. Then, the corresponding empirical formula was obtained by MATLAB, and parameters optimization was carried out as well. Besides, a lot of patents on machining thin-walled parts were studied. Results: The results shown that the prediction error of milling forces is about 15%, and 20% of milling temperature. In this case, the optimized milling parameters are as follows: ap=1 mm, ae=0.1 mm, n=12 000 r/min, and f=400 mm/min. It is of great significance to reduce the machining deformation and improve the machining quality of thin-walled parts.

Experimental Analysis of Damping Fixture for Thin-Walled Workpiece Milling

2016 ◽  
Vol 836-837 ◽  
pp. 296-303
Author(s):  
Dong Sheng Liu ◽  
Ming Luo ◽  
Ding Hua Zhang
Keyword(s):  
Manufacturing Industry ◽  
Machining Process ◽  
Machining Accuracy ◽  
Thin Wall ◽  
Machining Parameters ◽  
System Parameters ◽  
Thin Walled Structures ◽  
Machining System ◽  
Machining Test ◽  
Thin Walled

Thin-walled workpieces are widely used in the aerospace manufacturing industry in order to reduce the weight of structure and improve working efficiency. However, vibration is easy to occur in machining of thin-walled structures due to its low stiffness. Machining vibration will result in lower machining accuracy as well as machining efficiency. In order to reduce the machining vibrations of thin-wall workpieces, commonly used method is to select proper machining parameters according to the chatter stability lobes, which is generated according to the machining system parameters. However, this method requires exact system parameters to be determined, which are always changing in the machining process. In this paper, a special designed fixture with damping materials for the thin-walled workpiece is presented based on the machining vibration control theory, and analysis of the effect of vibration suppressing is obtained through the contrast of vibration tests of milling the thin-walled workpiece on the damping clamp. The damping material is used to consume vibration energy and provide support for thin-walled structure. Machining test was carried out for thin-walled structure machining to validate the effectiveness of the proposed method.

scholarly journals Surface Grinding Parameters Optimization of Austenitic Stainless Steel (AISI 304)

2020 ◽  
pp. 511-515
Author(s):  
Tushar Khule ◽  
Rahul Naravade ◽  
Sagar Shelke
Keyword(s):  
Surface Roughness ◽  
Large Scale ◽  
Metal Removal ◽  
Removal Rate ◽  
Parameters Optimization ◽  
Surface Grinding ◽  
Machining Process ◽  
Project Work ◽  
Depth Of Cut ◽  
Set Up

The assembling procedure of surface grinding has been set up in the large scale manufacturing of thin, rotationally even parts. Due to the complex set-up and geometrical, kinematical, dynamical influence parameters, surface grinding is rarely applied within limited-lot production. Surface crushing is a basic procedure for last machining of parts requiring smooth surfaces and exact resiliences.As contrasted and other machining forms, crushing is exorbitant activity that ought to be used under ideal conditions.. Although widely used in industry. The project work takes the following input processes parameters namely Work speed, feed rate and depth of cut. The main objective of this work is to predict the grinding behaviour and achieve optimal operating processes parameters. A software package is utilized which integrates these various models to simulate what happens during surface grinding processes. Predictions from this simulation will be further analysed by calibration with actual data. The main objective in any machining process is to maximize the Metal Removal Rate (MRR) and to minimize the surface roughness (Ra). In order to optimize these values Taguchi method, ANOVA is used. The surface roughness (Ra) value and Material Removal Rate (MRR), obtained from experimentation and confirmation test, for this the optimum control parameters are analysed.

Researches on Milling Machining of Planar Thin Wall Parts

2015 ◽  
Vol 760 ◽  
pp. 457-462
Author(s):  
Ionuţ Gabriel Ghionea ◽  
Ioan Tănase ◽  
Adrian Ghionea
Keyword(s):  
Case Studies ◽  
Cutting Tools ◽  
Fem Analysis ◽  
Experimental Tests ◽  
Cutting Parameters ◽  
Thin Wall ◽  
Machining Parameters ◽  
Thin Walls ◽  
Cutting Force Components ◽  
Force Components

In the paper are presented some experimental and by simulation results obtained in the machining by milling of plane surfaces of thin walls parts. Two case studies are considered: when the thin wall is vertical and then the thin wall is horizontal positioned. Some values of the cutting force components are established using a modern dynamometer and a data acquisition system. The elastic deformation values of the machined part are also determined by experimental tests and simulated in a FEM analysis. Depending on the data that geometrically define the part and the cutting tools, their materials and the cutting parameters, are set values of the cutting forces and powers. There are presented the results of values comparison obtained by measuring during the processes with those established by applying FEM. Both case studies results lead to some remarks and useful recommendations for determining the machining parameters and the needed conditions for the technological system in the processing of parts with thin walls and minimum deformations.

scholarly journals Effect of Different Cutting Speed towards Machinability of Titanium (Ti6Al4V) Curved Thin Wall using Trochoidal Milling Path

2019 ◽  
Vol 8 (6) ◽  
pp. 3392-3396
Keyword(s):  
Cutting Tool ◽  
Cutting Speed ◽  
Machining Process ◽  
Machining Accuracy ◽  
Hard Material ◽  
Thin Wall ◽  
Machining Parameters ◽  
Body Parts ◽  
Jet Engines ◽  
Machining Force

Aircraft parts and components used a lot of titanium as the material for body parts and engines. The materials offer rigidity, strength and light in weight. This unique characteristic was the major advantages in improving the payload capacity and improving the fuel consumption of the jet engines. The problem raised during the machining process of the material. Titanium is a hard material, elastic and poor thermal conductor. As the material is hard, higher machining force is required to perform the machining. Elasticity added the difficulties as it will spring away from the cutting tool which cause the tool to rub instead of cutting that can increased the heat. Thus, machining titanium alloy is expensive and difficult. This preliminary study looks into several machinability aspects and machining parameters for curved thin wall machining profile in the research. Machining accuracy and cutting tool wears were observed during the experiments. There are two set of machining parameters for the machining trials. At the same time, this research able to recommend the suitable machining parameters analysed from the experiments.

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.

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

2020 ◽  
Vol 17 (3) ◽  
pp. 8128-8139
Author(s):  
S. Chakraborty ◽  
S. Mitra ◽  
D. Bose
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Parameters ◽  
Dielectric Fluids ◽  
High Emission ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

The Emergence of Rabbinic Culture from the Perspective of Qumran

2015 ◽  
Vol 6 (2) ◽  
pp. 253-274
Author(s):  
Vered Noam
Keyword(s):  
Early Stage ◽  
Second Temple ◽  
Test Case ◽  
Literary Works ◽  
Jewish Culture ◽  
The Bible ◽  
Set Up

The rabbinic halakhic system, with its many facets and the literary works that comprise it, reflects a new Jewish culture, almost completely distinct in its halakhic content and scope from the biblical and postbiblical culture that preceded it. By examining Jewish legislation in the area of corpse impurity as a test case, the article studies the implications of Qumranic halakhah, as a way-station between the Bible and the Mishnah, for understanding how Tannaitic halakhah developed. The impression obtained from the material reviewed in the article is that the direction of the “Tannaitic revolution” was charted, its methods set up, and its principles established, at a surprisingly early stage, before the destruction of the Second Temple, and thus at the same time that the Qumran literature was created.

scholarly journals Energy efficient cutting parameter optimization

2021 ◽  
Author(s):  
Xingzheng Chen ◽  
Congbo Li ◽  
Ying Tang ◽  
Li Li ◽  
Hongcheng Li
Keyword(s):  
Energy Efficiency ◽  
Energy Consumption ◽  
Parameter Optimization ◽  
Energy Efficient ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Current Status ◽  
Cutting Parameter ◽  
Cutting Parameter Optimization

AbstractMechanical manufacturing industry consumes substantial energy with low energy efficiency. Increasing pressures from energy price and environmental directive force mechanical manufacturing industries to implement energy efficient technologies for reducing energy consumption and improving energy efficiency of their machining processes. In a practical machining process, cutting parameters are vital variables set by manufacturers in accordance with machining requirements of workpiece and machining condition. Proper selection of cutting parameters with energy consideration can effectively reduce energy consumption and improve energy efficiency of the machining process. Over the past 10 years, many researchers have been engaged in energy efficient cutting parameter optimization, and a large amount of literature have been published. This paper conducts a comprehensive literature review of current studies on energy efficient cutting parameter optimization to fully understand the recent advances in this research area. The energy consumption characteristics of machining process are analyzed by decomposing total energy consumption into electrical energy consumption of machine tool and embodied energy of cutting tool and cutting fluid. Current studies on energy efficient cutting parameter optimization by using experimental design method and energy models are reviewed in a comprehensive manner. Combined with the current status, future research directions of energy efficient cutting parameter optimization are presented.

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