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

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.

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

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.592-594.2733 ◽

2014 ◽

Vol 592-594 ◽

pp. 2733-2737 ◽

Cited By ~ 1

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.

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Modeling and optimization of temperature in end milling operations

Thermal Science ◽

10.2298/tsci190328244b ◽

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.

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Application of Teaching

International Journal of Materials Forming and Machining Processes ◽

10.4018/ijmfmp.2015070101 ◽

2015 ◽

Vol 2 (2) ◽

pp. 1-16 ◽

Cited By ~ 2

Author(s):

Nandkumar N. Bhopale ◽

Nilesh Nikam ◽

Raju S. Pawade

Keyword(s):

Tool Path ◽

End Milling ◽

Optimization Technique ◽

Milling Process ◽

Parameters Optimization ◽

Machining Parameters ◽

Machining Processes ◽

Conflicting Objectives ◽

Advanced Machining ◽

Teaching Learning

Recently advanced machining processes are widely used by manufacturing industries in order to produce high quality precise and very complex products. These advanced machining processes involve large number of input parameters which may affect the cost and quality of the products. Selection of optimum machining parameters in such advanced machining processes is very important to satisfy all the conflicting objectives of the process. This algorithm is inspired by the teaching-learning process and it works on the effect of influence of a teacher on the output of learners in a class. This paper presents the application of Response Surface Methodology coupled with newly developed advanced algorithm Teaching Learning Based Optimization Technique (TLBO) is applied for the process parameters optimization for ball end milling process on Inconel 718 cantilevers. The machining and tool related parameters like spindle speed, milling feed, workpiece thickness and workpiece inclination with tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate.

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Finite Element Analysis of a Frictionally Damped Slender Endmill

Volume 3: Design, Materials and Manufacturing, Parts A, B, and C ◽

10.1115/imece2012-86920 ◽

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.

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

International Journal of Vehicle Structures and Systems ◽

10.4273/ijvss.10.6.04 ◽

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.

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Chatter Investigation in Titanium Milling

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1019.318 ◽

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

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.

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EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

IIUM Engineering Journal ◽

10.31436/iiumej.v18i1.638 ◽

2017 ◽

Vol 18 (1) ◽

pp. 147-154

Author(s):

Mohammad Yeakub Ali ◽

Wan Norsyazila Jailani ◽

Mohamed Rahman ◽

Muhammad Hasibul Hasan ◽

Asfana Banu

Keyword(s):

Surface Roughness ◽

Feed Rate ◽

Spindle Speed ◽

Machining Process ◽

Depth Of Cut ◽

Microfluidic Channels ◽

Machining Parameters ◽

Machining Processes ◽

Dry Cutting ◽

Minimum Quantity

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

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

Dinamika Teknik Mesin ◽

10.29303/d.v6i1.24 ◽

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%.

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Machining Process for a Thin-Walled Workpiece Using On-Machine Measurement of the Workpiece Compliance

International Journal of Automation Technology ◽

10.20965/ijat.2019.p0631 ◽

2019 ◽

Vol 13 (5) ◽

pp. 631-638 ◽

Cited By ~ 1

Author(s):

Takuma Umezu ◽

◽

Daisuke Kono

Keyword(s):

Measurement System ◽

End Milling ◽

Numerical Control ◽

Cutting Conditions ◽

Machining Process ◽

Experimental Result ◽

Depth Of Cut ◽

Machining Processes ◽

Workpiece Vibration ◽

Thin Walled

Demand for highly productive machining of thin-walled workpieces has been growing in the aerospace industry. Workpiece vibration is a critical issue that could limit the productivity of such machining processes. This study proposes a machining process for thin-walled workpieces that aims to reduce the workpiece vibration during the machining process. The workpiece compliance is measured using an on-machine measurement system to obtain the cutting conditions and utilize the same for suppressing the vibration. The on-machine measurement system consists of a shaker with a force sensor attached on the machine tool spindle, and an excitation control system which is incorporated within the machine tool’s numerical control (NC). A separate sensor to obtain the workpiece displacement is not required for the estimation of the displacement. The system is also capable of automatic measurement at various measurement points because the NC controls the positioning and the preloading of the shaker. The amplitude of the workpiece vibration is simulated using the measured compliance to obtain the cutting conditions for suppressing the vibration. An end milling experiment was conducted to verify the validity of the proposed process. The simulations with the compliance measurement using the developed system were compared to the results of a conventional impact test. The comparison showed that the spindle rotation speed for suppressing the vibration could be successfully determined; but, the axial depth of cut was difficult to be determined because the simulated vibration amplitude was larger than that found in the experimental result. However, this can be achieved if the amplitude is calibrated by one machining trial.

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Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

International Journal of Modeling Simulation and Scientific Computing ◽

10.1142/s1793962320500117 ◽

2020 ◽

Vol 11 (02) ◽

pp. 2050011

Author(s):

Padmaja Tripathy ◽

Kalipada Maity

Keyword(s):

Finite Element ◽

Cutting Forces ◽

Inconel 718 ◽

Cutting Speed ◽

Fem Analysis ◽

Milling Process ◽

Machining Process ◽

Micro Milling ◽

Depth Of Cut ◽

Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

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