Experiment Study on Deflection of Aluminum Alloy Thin-Wall Workpiece in Milling Process

2011 ◽  
Vol 697-698 ◽  
pp. 129-132 ◽  
Author(s):  
Bing Han ◽  
Cheng Zu Ren ◽  
X.Y. Yang ◽  
Guang Chen
Keyword(s):  
Aluminum Alloy ◽  
Coordinate Measuring Machine ◽  
Milling Process ◽  
Cnc Machining ◽  
Machining Accuracy ◽  
Thin Wall ◽  
Machining Center ◽  
Machining Errors ◽  
Alloy Material ◽  
Measuring Machine

The deflection of Aluminum alloy thin-wall workpiece caused by the milling force leads to additional machining errors and reduces machining accuracy. In this paper, a set of experiments of milling thin-wall workpiece were carried out to study the deflection of thin-wall workpiece. The workpieces, with different types of material and different thicknesses, were machined on CNC machining center. The deflections of workpiece were measured by a three-coordinate measuring machine. Effects of Aluminum alloy material and thickness on deflection are discussed based on the experimental data.

Layer Based Robot Machining for Rapid Prototyping

2000 ◽  
Author(s):  
Y. Song ◽  
Y. H. Chen
Keyword(s):  
Rapid Prototyping ◽  
Large Scale ◽  
Tool Path ◽  
Coordinate Measuring Machine ◽  
Cnc Machining ◽  
Stl File ◽  
Machining Center ◽  
Machining System ◽  
Robot Machining ◽  
Measuring Machine

Abstract Many useful methods have been applied to Rapid Prototyping (RP) technologies in recent years, and each of them has its own features. To solve the problem in large-scale prototyping, a robotic machining center with layer based algorithms is developed. Using STereoLithography (STL) file, the surfaces of a model are represented by triangles. Calculating the intersection between a series of parallel planes and the STL file, a STereolithography Contour (SLC) file of the model is generated where the model is represented as a series of contours on a set of parallel planes. Instead of using the popular RP technologies, traditional Computer Numerical Controlled (CNC) machining method is applied in machining each layer of the model. With visibility calculation, the thickness of each material layer is selected. When collision is detected for a point on the tool path, the orientation of the tool is modified. With the machining of a vase model, the effectiveness of the proposed algorithm is demonstrated. Errors of the robot machining system are analyzed by a Coordinate Measuring Machine (CMM) and a surface texture measuring machine.

scholarly journals Application of Piezoelectric Fast Tool Servo for Turning Non-Circular Shapes Made of 6082 Aluminum Alloy

2021 ◽  
Vol 11 (16) ◽  
pp. 7533
Author(s):  
Marcin Pelic ◽  
Bartosz Gapiński ◽  
Wojciech Ptaszyński
Keyword(s):  
Aluminum Alloy ◽  
Coordinate Measuring Machine ◽  
Machining Accuracy ◽  
Laser Sensor ◽  
Servo Drive ◽  
Order Polynomial ◽  
Measuring Machine ◽  
6082 Aluminum Alloy ◽  
Piezoelectric Drive ◽  
Design And Testing

The paper presents the design and testing of a new servo drive for turning non-circular shapes. The presented solution is based on a commercially available piezoelectric drive unit with a stroke equal to 1000 µm and a resonant frequency of 150 Hz. The device was used in a conventional turning lathe and installed in a tool turret. The performance of the proposed tool was tested while turning multiple non-circular contours from a cylindrical shaft made of 6082 aluminum alloy. The machining accuracy was tested online using a laser sensor and offline with a coordinate measuring machine. The additional aim of those tests was also to verify if the application of an online transducer can allow a confident preliminary assessment of as-machined geometry. The drive positioning accuracy was compensated using 6th order polynomial what resulted in the fabrication of non-circular contours with an accuracy of no less than 39.8 µm when operating below the limit frequency of the drive (<9 Hz). It was found out that the deviations of the profile from ideal geometries increase linearly with frequency when turning at higher than the limit frequency.

Research on S-gear design, manufacturing and measuring based on NC machining center

2020 ◽  
pp. 095440542098134
Author(s):  
Shao-ying Ren ◽  
Yan-zhong Wang ◽  
Yuan Li
Keyword(s):  
Convex Surface ◽  
Coordinate Measuring Machine ◽  
Nc Machining ◽  
Tooth Profile ◽  
Numerical Control ◽  
Machining Center ◽  
Involute Gear ◽  
Measuring Machine ◽  
Gear Contact ◽  
Nc Machining Center

This article presents a method of design, manufacturing, and measuring S-gear. S-gear is a kind of gear whose tooth profile is an S-shaped curve. The sine (cosine) gear, cycloid gear, polynomial gear, and circular arc gear are all S-gears in essence. In the S-gear transmission, the concave surface of one gear and the convex surface of the other gear contact each other. Therefore, the power transmitted by S-gear is much larger than that of the convex-convex-contact involute gear. Some scholars have studied the characteristics of S-gear, but few have explored its manufacturing. In this article, the Numerical Control (NC) machining technology of S-gear is studied in detail for its industrial application. The polynomial curve is used to construct the tooth profile of the S-gear based on the Gear Meshing Theory. The mathematical model of polynomial S-gear is established, by which involute gear can be represented as a special S-gear. The steps of generating NC codes are described. Then, the S-gear sample is processed with an NC machining center. Finally, the sample is measured with a Coordinate Measuring Machine (CMM), and the measurement results show that the accuracy of the S-gear processed by the NC machining center reaches ISO6. This research provides a feasible approach for the design, manufacturing, and measuring of S-gear.

Assessment of Free-Form Surfaces’ Reconstruction Accuracy

2017 ◽  
Vol 24 (2) ◽  
pp. 303-312 ◽  
Author(s):  
Artur Wójcik ◽  
Magdalena Niemczewska-Wójcik ◽  
Jerzy Sładek
Keyword(s):  
Accuracy Assessment ◽  
Coordinate Measuring Machine ◽  
System Structure ◽  
Free Form ◽  
Correction Algorithm ◽  
Reconstruction Accuracy ◽  
Machining Center ◽  
Cad Cam ◽  
Measuring Machine ◽  
Free Form Surfaces

AbstractThe paper presents the problem of assessing the accuracy of reconstructing free-form surfaces in the CMM/CAD/CAM/CNC systems. The system structure comprises a coordinate measuring machine (CMM) PMM 12106 equipped with a contact scanning probe, a 3-axis Arrow 500 Vertical Machining Center, QUINDOS software and Catia software. For the purpose of surface digitalization, a radius correction algorithm was developed. The surface reconstructing errors for the presented system were assessed and analysed with respect to offset points. The accuracy assessment exhibit error values in the reconstruction of a free-form surface in a range of ± 0.02 mm, which, as it is shown by the analysis, result from a systematic error.

Optimization of Milling Process for Aluminum Alloy Frame Part Based on Milling Force Analysis

2014 ◽  
Vol 575 ◽  
pp. 437-441
Author(s):  
Yi Shu Hao ◽  
Guo Qing Tang ◽  
Meng Zhang
Keyword(s):  
Aluminum Alloy ◽  
Selection Method ◽  
Milling Process ◽  
Parameter Selection ◽  
Force Analysis ◽  
Milling Force ◽  
Finite Element Software ◽  
Milling Parameters ◽  
Machining Errors ◽  
Thin Walled

In order to solve the problem of size guarantee related to thin-walled structure in traditional milling parameter selection, specific aluminum alloy frame part contains curved surface and thin-walled structure is studied. Numerical analysis is used in milling parameter selection method. Machining errors are calculated and checked based on milling force analysis. The milling process is simulated using finite element software. And aluminum alloy frame part processing is optimized from the angle of milling parameters according to the simulation results. Optimized milling parameters scheme is acquired, the results show that both machining precision and efficiency of the frame part are improved.

Monitoring and Control of Thermal Expansion Effect on Machining Process of Aluminum Alloy Parts

2015 ◽  
Vol 809-810 ◽  
pp. 33-38 ◽  
Author(s):  
Ştefan Adrian Moldovan ◽  
Vasile Năsui
Keyword(s):  
Thermal Expansion ◽  
Aluminum Alloy ◽  
Milling Process ◽  
Machining Process ◽  
Machining Accuracy ◽  
Technological Problem ◽  
Monitoring And Control ◽  
Machining Processes ◽  
Thermal Expansion Effect ◽  
Expansion Effect

In this paper we present a technological problem encountered in the machining accuracy of the parts for aerospace made of aluminum alloy extruded profile with length up to 10 meters. Those parts have very tight tolerances and on milling process appear several factors that influence the repeatability of machining processes, the main one being the thermal expansion effect.

Crankshaft Mould CNC Machining Based on CAD/CAM Technique

2016 ◽  
Vol 693 ◽  
pp. 1704-1710
Author(s):  
Ting Ting Guo ◽  
Xian Ying Feng ◽  
Teng Jiao Sun
Keyword(s):  
Tool Path ◽  
Cutting Tool ◽  
Cnc Machining ◽  
Machining Accuracy ◽  
Technological Parameters ◽  
Tool Selection ◽  
Machining Center ◽  
Method Selection ◽  
Cad Cam

Taking the CY4105 crankshaft mould as the research target, this paper introduced the CNC machining method based on CAD/CAM technique. At first, structure of the mould was introduced. Then, machining method was introduced, including blank setting method, cutting tool selection, machining method selection and technological parameters setting method. After that, generation method of the mould machining programs was introduced, including tool path and G codes generation. At last, the mould was machined by a vertical machining center, and the results show that the machining accuracy is high.

Comparative Statistical Analysis of Test Parts Manufactured in Production Environments

2004 ◽  
Vol 126 (1) ◽  
pp. 189-199 ◽  
Author(s):  
David E. Gilsinn ◽  
Alice V. Ling
Keyword(s):  
Statistical Analysis ◽  
Machine Tool ◽  
Coordinate Measuring Machine ◽  
Hole Center ◽  
Machining Center ◽  
Production Environments ◽  
Measuring Machine ◽  
Comparative Statistical Analysis ◽  
Uncertainty Models ◽  
Propagation Of Uncertainties

Estimating error uncertainties arising in production parts is not a well-understood process. An approach to estimate these uncertainties was developed in this study. Machine tool error components were measured on a three-axis vertical machining center. Multiple parts were produced on the measured machining center then measured on a coordinate measuring machine. Uncertainty models for hole-center to hole-center lengths and orthogonalities were developed using measured machine tool errors. These estimated uncertainties were compared against measured uncertainties. The main conclusion from the study is that the Law of Propagation of Uncertainties can be used to estimate machining uncertainties.

A Study of Chatter Stability Domain in Different Phases of Milling Process of Thin-Wall Component

2013 ◽  
Vol 711 ◽  
pp. 137-142
Author(s):  
Wei Wei Liu ◽  
Yuan Yuan Cai ◽  
Feng Li ◽  
Xiao Yan Li ◽  
Xu Sheng Wan
Keyword(s):  
Dynamic Model ◽  
Resonance Region ◽  
Stability Domain ◽  
Milling Process ◽  
Machining Accuracy ◽  
Thin Wall ◽  
Chatter Stability ◽  
Aero Engine ◽  
Cutting Chatter ◽  
Wall Components

Aeronautical thin-wall components are widely used in Aero-Engine, and the machining stability of the thin-wall components is a difficulty issue. In this paper, a single freedom dynamic model is set up to describe the dynamics of thin-wall milling process, and the stability of the dynamic model is analyzed with the discretization method. Then the modal parameters are gained in the different milling phases and the resonance region of spindle speed is proposed. Optimize the milling parameters with the chatter stability domain at different milling phases. The result shows that the cutting chatter can be restrained if getting the spindle speedcutting depth parameters considering the superposition area of chatter stability domains and avoiding the resonance region in the different milling phases. At last, the method is applied in Aero-Engine thin-wall blade milling, the metal remove rate increases greatly and the machining accuracy is improved greatly.

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