The Influence Factor Analysis for Coupling Performance of HSK Tool System

2011 ◽  
Vol 480-481 ◽  
pp. 1225-1229 ◽  
Author(s):  
Chun Jiang Zhou
Keyword(s):  
High Speed ◽  
Influence Factor ◽  
Torsional Stiffness ◽  
Radial Deformation ◽  
High Speed Machining ◽  
Coupling System ◽  
Element Simulation ◽  
Coupling Performance ◽  
Tool Shank

The coupling performance of tool system is the important factor for the machining quality of high speed machining. Based on the deformation of contact surfaces of HSK tool system, the paper makes the academic analysis by elasticity theory and finite element simulation to high speed spindle/tool shank coupling system. The property of the contact stress and the radial deformation as well as the torsional stiffness with different amount of interference has been analyzed. In this method, the paper brings forward how the amount of interference will affect the coupling performance. Thus, it will give academic evidence to design and select tool system in the process of high speed machining.

Evaluation and Improvement of Productivity in High-Speed NC Machining

1999 ◽  
Vol 122 (3) ◽  
pp. 556-561 ◽  
Author(s):  
X. Yan ◽  
K. Shirase ◽  
M. Hirao ◽  
T. Yasui
Keyword(s):  
High Speed ◽  
Nc Machining ◽  
Cutting Conditions ◽  
High Speed Machining ◽  
Machining Time ◽  
Time Constants ◽  
Nc Program ◽  
Kinematic Factor ◽  
Two Factors

The productivity of machining centers is influenced inherently by the quality of NC programs. To evaluate productivity, first an effective feedrate factor and a productivity evaluation factor are proposed. It has been found that in high-speed machining, these two factors depend on a kinematic factor which is a function of (1) command feedrate, (2) average per-block travel of the tool, (3) moving vectorial variation of the tool, and (4) ac/deceleration or time constants. Then an NC program simulator has been developed to evaluate productivity. With the simulator, the machining time can be calculated accurately and the cutting conditions can be extracted. Finally, three NC programs were implemented on high-speed machining centers and analyzed by the simulator. It was found that in mold and die machining, the productivity can be improved by increasing the acceleration and average travel and reducing the vectorial variation of the tool rather than the command feedrate. [S1087-1357(00)01303-4]

The role of material model in the finite element simulation of high-speed machining of Ti6Al4V

2016 ◽  
Vol 230 (17) ◽  
pp. 2959-2967 ◽  
Author(s):  
Chong-Yang Gao ◽  
Liang-Chi Zhang ◽  
Peng-Hui Liu
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
High Speed ◽  
Material Model ◽  
Machining Process ◽  
High Speed Machining ◽  
Serrated Chip ◽  
Finite Element Program ◽  
Element Simulation ◽  
Improved Model

This paper provides a comprehensive assessment on some commonly used thermo-viscoplastic constitutive models of metallic materials during severe plastic deformation at high-strain rates. An hcp model previously established by us was improved in this paper to enhance its predictability by incorporating the key saturation characteristic of strain hardening. A compensation-based stress-updating algorithm was also developed to introduce the new hcp model into a finite element program. The improved model with the developed algorithm was then applied in finite element simulation to investigate the high-speed machining of Ti6Al4V. It was found that by using different material models, the simulated results of cutting forces, serrated chip morphologies, and residual stresses can be different too and that the improved model proposed in this paper can be applied to simulate the titanium alloy machining process more reliably due to its physical basis when compared with some other empirical Johnson–Cook models.

Modal Analysis of BT Spindle-Toolholder Interface Based on Abaqus/Standard

2013 ◽  
Vol 662 ◽  
pp. 632-636
Author(s):  
Yong Sheng Zhao ◽  
Jing Yang ◽  
Xiao Lei Song ◽  
Zi Jun Qi
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Modal Analysis ◽  
Dynamic Characteristics ◽  
High Speed ◽  
Element Model ◽  
Contact Theory ◽  
High Speed Machining ◽  
The Finite Element Model

The quality of high speed machining is directly related to dynamic characteristics of spindle-toolholder interface. The paper established normal and tangential interactions of BT spindle-toolholder interface based on finite element contact theory, and analysed free modal in Abaqus/Standard. Then the result was compared with the experimental modal analysis. It shows that the finite element model is effective and could be applied in the future dynamic study of high-speed spindle system.

Prevention of Material Deterioration in ECM of Sintered Carbide with Iron Ions

2017 ◽  
Vol 11 (1) ◽  
pp. 67-73 ◽  
Author(s):  
Akihiro Goto ◽  
◽  
Atsushi Nakata ◽  
Sicong Wang ◽  
Nagao Saito ◽  
...  
Keyword(s):  
High Speed ◽  
Electrochemical Machining ◽  
High Speed Machining ◽  
Conductive Liquid ◽  
Sintered Carbide ◽  
High Speeds ◽  
Quality Degradation ◽  
Fe Ions ◽  
Electrical Source

This study focuses on electrochemical machining as a method of processing sintered carbide at high speeds. Previous studies have suggested the possibility of using electrochemical machining to achieve high-speed machining of sintered carbide. However, there has been strong resistance in industry against bringing sintered carbide into contact with a conductive liquid. This is because the material quality of sintered carbide is degraded by the elution of Co when it is brought into contact with a conductive liquid.In previous reports, the authors have shown that it is possible to control two modes of Co elution occurring during electrochemical machining: the elution from sintered carbide when it comes into contact with an electrolyte, and the selective elution of Co due to difference in the speeds of WC dissolution and elution of Co when sintered carbide is connected to an electrical source for processing. It was shown that it is possible to control the elution Co in sintered carbide when it comes into contact with an electrolyte by adding Co ions to the electrolyte to increase the concentration of Co ion, and that it is possible to prevent the excessive elution of Co by using a bipolar electrical source for machining. Although we showed that it is possible to carry out electrochemical machining of sintered carbide without degrading its quality, adding of large amounts of Co ions to the electrolyte entails a high cost. In this report, therefore, we describe the addition of Fe ions instead of Co ions to perform electrochemical machining of sintered carbide without quality degradation.

Finite Element Simulation and Experiment of Chip Formation during High Speed Cutting of Hardened Steel

2010 ◽  
Vol 29-32 ◽  
pp. 1838-1843 ◽  
Author(s):  
Chun Zheng Duan ◽  
Hai Yang Yu ◽  
Yu Jun Cai ◽  
Yuan Yuan Li
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Chip Morphology ◽  
Hardened Steel ◽  
High Speed Machining ◽  
Serrated Chip ◽  
High Speed Cutting ◽  
Element Simulation ◽  
Aisi 1045

As an advanced manufacturing technology which has been developed rapidly in recent years, high speed machining is widely applied in many industries. The chip formation during high speed machining is a complicated material deformation and removing process. In research area of high speed machining, the prediction of chip morphology is a hot and difficult topic. A finite element method based on the software ABAOUS which involves Johnson-Cook material model and fracture criterion was used to simulate the serrated chip morphology and cutting force during high speed cutting of AISI 1045 hardened steel. The serrated chip morphology and cutting force were observed and measured by high speed cutting experiment of AISI 1045 hardened steel. The effects of rake angle on cutting force, sawtooth degree and space between sawteeth were discussed. The investigation indicates that the simulation results are consistent with the experiments and this finite element simulation method presented can be used to predict the chip morphology and cutting force accurately during high speed cutting of hardened steel.

Vibration Control of HSM of Thin-Wall Titanium Alloy Components Based on Finite Element Simulation

2016 ◽  
Vol 836-837 ◽  
pp. 304-309 ◽  
Author(s):  
Kang Zhao ◽  
Hong Hua Su ◽  
Lin Jiang He ◽  
Ying Zhi Liu
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
High Speed ◽  
Element Model ◽  
Fixture Design ◽  
Thin Wall ◽  
Element Simulation ◽  
Flexible Workpiece ◽  
Fixture System

During high-speed machining, the vibration will result in poor workpiece surface and damage the cutting tool as well as the machine tool. It will limit the productivity and lower the quality of thin-wall titanium alloy components. Moreover, vibration occurrence is strongly affected by the dynamic response of the whole system, particularly the stiffness of workpiece-fixture system. Improper fixture layout is prone to generate vibration, especially for the flexible workpiece. Hence, it’s necessary to suppress the vibration and improve the fixture design. In this work, a finite element model of the workpiece-fixture system is built. Based on this model, the laws of the natural frequency and vibration modals under different fixturing methods are obtained, which can be used to refine fixture design. With several additional auxiliary supports, the stiffness of the workpiece-fixture system is improved and the result showed that, the natural frequencies of thin-wall titanium alloy components can be improved to a level which is too high to be reached by tool’s excitation. The result of this study is helpful to design the optimum fixture scheme of thin-wall titanium alloy components.

Finite Element Simulation of High Speed Machining of Ti6Al4V Alloy and the Corresponding Experimental Study

2016 ◽  
Vol 836-837 ◽  
pp. 444-451 ◽  
Author(s):  
Long Hui Meng
Keyword(s):  
Finite Element ◽  
Constitutive Model ◽  
Finite Element Simulation ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Ti6al4v Alloy ◽  
Machining Process ◽  
High Speed Machining ◽  
Hopkinson Pressure Bar ◽  
Element Simulation

Finite element simulation of high speed machining of Ti6Al4V alloy was carried out based on the software of Abaqus. The Johnson-Cook constitutive model was chosen for the material of Ti6Al4V, the parameters of the model were obtained through the SHPB (Split Hopkinson Pressure Bar) experiment. The similarity of the chips obtained from the simulation and that obtained from the experiment indicated that the parameters of the Johnson-Cook constitutive model for Ti6Al4V alloy were reliable. Different cutting parameters and different tool geometric parameters were used in the simulations to find out their effects to the simulation results. Also a comparison was made between the results got form the simulations results and the experimental results, a good agreement between them indicated that the finite element simulation of high speed machining of Ti6Al4V is reliable, so it can be concluded that the finite element simulations of high speed machining can be widely used in practice to study the more about the machining process and reduce the experimental expenses.

Unbalance Response of HSK Hydraulic Chuck Tooling System for High-Speed Machining

2016 ◽  
Vol 836-837 ◽  
pp. 387-393
Author(s):  
De Fei Tao ◽  
Deng Sheng Zheng ◽  
Jian Chen ◽  
Gui Cheng Wang
Keyword(s):  
High Speed ◽  
Linear Growth ◽  
Excitation Frequency ◽  
Numerical Control ◽  
High Speed Machining ◽  
The Finite Element Method ◽  
Displacement Response ◽  
Tooling System ◽  
Balancing Control

High-speed chuck is an important component of high speed machining tooling system. Its properties directly affect the performance and processing quality of advanced numerical control machine. Using the finite element method, the research analyzed influence of inertial centrifugal force caused by unbalance on the dynamic characteristics of HSK hydraulic clamping chuck tooling system and systematically revealed variation of shank, chuck and blade point displacement. It is found that blade point, as well as chuck and shank displacement response amplitude of tooling system rises as a whole with the increase of excitation frequency; the dynamic displacement response increment shows linear growth with unbalance amount, which provides a theoretical basis for optimum design and balancing control of HSK hydraulic chunk tooling system.

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