Identification of Stability Lobes in High-Speed Milling Flexible Parts with Bull-Nose End Mills

2010 ◽  
Vol 443 ◽  
pp. 297-301 ◽  
Author(s):  
Yi Wan ◽  
Qing Hua Song ◽  
Zhan Qiang Liu
Keyword(s):  
High Speed ◽  
Production Costs ◽  
Tool Geometry ◽  
Force Model ◽  
High Speed Machining ◽  
High Speed Milling ◽  
Stability Lobes ◽  
Flexible Parts ◽  
End Mills ◽  
Monolithic Components

Flexible parts such as turbine blade, blisk and monolithic components are widely used in the aeronautical industry, and high Speed Machining (HSM) technology is used to increase productivity and reduce production costs. Chatter is an undesirable phenomenon in high speed machining processes because of deteriorative surface finish, early cutting tool failure and unexpected machine tool damage. It can be avoided in higher speed milling processes if stability lobes is determined. In this paper, a non-linear regenerative force model is applied to a bull-nose tool geometry in order to obtain the machine operation stability lobes. An analytical-experimental method is proposed to obtain the stability lobes during high speed milling flexible parts with bull-nose end mills. The method is calculated and validated.

Surface Integrity of a High Speed Milling FC300 Gray Cast Iron

2013 ◽  
Vol 465-466 ◽  
pp. 642-646 ◽  
Author(s):  
Abu Bakar Mohd Hadzley ◽  
Mohamad Raffi Nurul Fatin ◽  
Raja Abdullah Raja Izamshah ◽  
Nur Izan Syahriah Hussein ◽  
Ahmad Siti Sarah ◽  
...  
Keyword(s):  
Cast Iron ◽  
Automotive Industry ◽  
High Speed ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Surface Finishing ◽  
High Speed Machining ◽  
High Productivity ◽  
Die Surface ◽  
End Mills

The high speed machining (HSM) of gray cast iron for manufacture mold and dies involve many different cutting tool from deep hole drills to smallest ball nose end mills [. Due to the demand of fast and high productivity, high speed machining (HSM) has been increasingly used to produce mold and dies that are mostly used in automotive industry especially for stamping dies components. The process of HSM sometimes combined together with manual polishing to enhance the die surface into fine mirror finish. Although the manual polishing strongly depends by experience and skill of workers, this technique is the preferable option for polishing of moulds and dies. However, such extensive manual polishing will provide some drawback because of many human factors such as pressure and technique of polishing individual person uses. Therefore, the application high speed machining in manufacturing is still demanding as it can improve surface finishing by reducing manual polishing, reportedly account for up to 30% of the total time [2].

Reduction of Vibrations due to Unbalance with Anti-Vibration Clearance Angle in High Speed Milling

2016 ◽  
Vol 836-837 ◽  
pp. 161-167
Author(s):  
Anna Thouvenin ◽  
Xin Li ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Material Removal ◽  
High Speed ◽  
Removal Rate ◽  
Machining Process ◽  
High Speed Machining ◽  
Machining Processes ◽  
High Speed Milling ◽  
Clearance Angle ◽  
Fast Solution ◽  
Considerable Problem

High speed milling is one of the most commonly used machining processes in many fields of the industry. It is regarded as a simple and fast solution to achieve a high material removal rate, which allows an important production of parts. Unbalance is a problem in any machining process but becomes a considerable problem when reaching high speed machining. The vibrations due to an unbalanced tool or tool holder can result in a poor surface quality and a damaged tool. The damping of the vibrations can be achieved with a specially designed tool showing an anti-vibration clearance angle. This paper shows the influence of the anti-vibration clearance angle by a computational model and a set of experiments to see if it can reduce or suppress the vibrations due to unbalance in high speed milling.

Creation of Ball End Mills for High Speed Milling by means of 3D-CAD/CAM System

2002 ◽  
Vol 2002.4 (0) ◽  
pp. 107-108
Author(s):  
Yi Lu ◽  
Yoshimi Takeuchi ◽  
Ichiro Takahashi ◽  
Masahiro Anzai
Keyword(s):  
High Speed ◽  
High Speed Milling ◽  
3D Cad ◽  
Cad Cam ◽  
End Mills

Tool Overhang Effect on Cutting Force in High Speed Milling

2010 ◽  
Vol 34-35 ◽  
pp. 616-620 ◽  
Author(s):  
Zhen Yu Zhao ◽  
Ying Bin Du ◽  
Lei Ming Zhang ◽  
Bai Liu
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Milling Process ◽  
Processing Capacity ◽  
High Speed Machining ◽  
High Speed Milling ◽  
Rational Use ◽  
High Speed Impact ◽  
Overhang Length

Based on the amount of tool overhang under different high speed machining experiment, the overhang length on the high speed impact of cutting force in milling process is studies. On the basis, the proposed tool overhang and optimum program are proposed in high speed milling, through the rational use of tools to improve processing capacity of the tool.

Design of controllable end mills with superhard cutters for high-speed machining

2015 ◽  
Vol 35 (4) ◽  
pp. 292-294
Author(s):  
V. A. Grechishnikov ◽  
I. V. Chulin ◽  
A. I. Isakov
Keyword(s):  
High Speed ◽  
High Speed Machining ◽  
End Mills

Residual Stress Evaluation on X 36 Cr Mo 17 HSM Finished Mould Steel

2006 ◽  
Vol 514-516 ◽  
pp. 559-563
Author(s):  
Joao P. Nobre ◽  
António Castanhola Batista ◽  
Carlos Capela ◽  
Marcelo Calvete Gaspar
Keyword(s):  
Residual Stress ◽  
Stress State ◽  
High Speed ◽  
Multilayer Coating ◽  
Work Piece ◽  
Machining Parameters ◽  
High Speed Milling ◽  
Residual Stress State ◽  
Limit Value ◽  
End Mills

The presented study was carried out in an industrial environment, using existing equipments, tools and materials. A set of tests was performed based on production demands and restrictions, aiming to achieve the lowest surface roughness and beneficial residual stress state. The experimental test surfaces were obtained using high-speed milling (HSM) and precision surface grinding on a DIN X 36 CrMo 17 steel work piece, widely used in injection moulding industry. The grinded surface was considered as a reference surface in order to evaluate the high-speed milling performance. For HSM tests, two types of tools were selected: tungsten carbide end mills with and without a TiAlN multilayer coating. The selected HSM main parameters ranged an upper, middle and lower limit value, considering the standard working values. The residual stress state at machined surfaces was evaluated by X-ray diffraction (XRD). Experimental results are discussed in order to achieve a procedure to select the optimal machining parameters that meet manufacturing specifications.

A Method of Tool Breakage Detection in CNC High-Speed Milling

2011 ◽  
Vol 138-139 ◽  
pp. 598-603
Author(s):  
Qi Gao
Keyword(s):  
Condition Monitoring ◽  
High Speed ◽  
Tool Condition Monitoring ◽  
Fast Method ◽  
High Speed Machining ◽  
Research Projects ◽  
Tool Breakage ◽  
High Speed Milling ◽  
Motor Current ◽  
Tool Condition

Tool condition monitoring, mainly tool breakagedetection for high-speed machining (HSM), is an importantproblem to solve; however, the techniques or types ofsensors applied in other research projects present certaininconveniences. In order to improve tool breakage monitoringsystems, a simple, effective, and fast method ispresented herein. This method is based on the discretewavelet transform (DWT) and statistical methodologies.The effectiveness of the method is based on the measurementsof the feed-motor current signals using inexpensivesensors. It is well-known that during the cutting process,the motor current is related to the tool condition.

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