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.

On-Machine Estimation of Workpiece Deformation for Thin-Walled Parts Considering Fixture Clamping Sequence

2020 ◽  
Author(s):  
Jingkai Zeng ◽  
Koji Teramoto ◽  
Dongjin Wu ◽  
Hiroki Matsumoto
Keyword(s):  
Manufacturing Industry ◽  
Structural Characteristics ◽  
Process Variations ◽  
Point Of View ◽  
Machining Process ◽  
Machining Accuracy ◽  
Near Net Shape ◽  
Modern Manufacturing ◽  
Thin Walled ◽  
Clamping Sequence

Abstract Due to the higher structure efficiency and lightweight characteristic, thin-walled parts are widely used in the modern manufacturing industry. However, from another point of view, these parts are complex in structure, weak stiffness and high precision demand. During the machining process, because of the material properties and structural characteristics, the action of elastic deformation in machining is heavily affected by the accuracy of thin-walled parts. Recently, novel near-net-shape machining methods which can be applicable to small-lot production such as thin-walled casting, additive manufacturing, and so on becomes common technology. Finish machining of these thin-walled and complex shape workpiece is an important target of machining. In the small lot production, most of fixturing process is executed as manual operations, which generate large process variations. These variations lead to deteriorate machining accuracy. Especially, the wrong operation for the fixture clamping sequence generates different workpiece deformation. The objective of this research is to estimate actual workpiece deformation by utilizing locally measured strains and fixturing simulation in order to detect unallowable workpiece deformation caused by the wrong clamping sequence. In this research, workpiece deformations for different clamping sequences are evaluated based on the engineering experiments. Verifications of estimated workpiece deformations are carried out. Through this research, we can effectively estimate the workholding situation of the thin-walled parts during the machining process.

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.

Discussion on NC Machining Process of Thin Walled Parts Technical Measures

2014 ◽  
Vol 701-702 ◽  
pp. 864-868
Author(s):  
Da Lin Zhang ◽  
Ke Gao ◽  
Tian Rui Zhou
Keyword(s):  
Industrial Production ◽  
Nc Machining ◽  
Machining Process ◽  
Precision Machining ◽  
Thin Wall ◽  
Machining Precision ◽  
Thin Walled ◽  
Technical Measures

Thin wall parts are used more and more extensively in industrial production, analyze the influence of precision machining of thin-walled parts not higher factor, through the example of how to improve the machining precision of thin-wall parts, and gives the specific measures to solve practical problems.

Optimal Clamping Scheme of Thin-Walled Cavity Workpiece

2011 ◽  
Vol 189-193 ◽  
pp. 2116-2120
Author(s):  
Shi Min Geng ◽  
Jun Wang
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Machining Process ◽  
Machining Accuracy ◽  
Finite Element Models ◽  
Thin Walled ◽  
Clamping Sequence

The thin-walled cavity workpiece with insufficient rigid property is liable to deform during the machining process and the request of accuracy is very strict. The paper takes typical aeronautic aluminum-alloy for example, fixture is an important consideration in the operation. To reveal the influences of locating points, clamping sequence and loading ways on the distortion of thin-walled cavity part, finite element models were established to simulate the clamping operation. The result shows the preferable scheme is that the distance of the clamping locations are far each other, clamping forces are firstly applied on the surface with high rigid and all clamping forces are applied in many steps. The scheme can effectively control the deformation of clamp ,and furthermore improve the machining accuracy.

Synchronous Adjustment of Milling Tool Path Based on the Relative Deviation

2011 ◽  
Vol 133 (5) ◽  
Author(s):  
Xiao-Jin Wan ◽  
Cai-Hua Xiong ◽  
Lin Hua
Keyword(s):  
Tool Path ◽  
Cutting Tool ◽  
Cnc Machining ◽  
Numerical Control ◽  
Machining Process ◽  
Machining Accuracy ◽  
Source File ◽  
Modern Computer ◽  
Adjustment Strategy ◽  
Machining System

In machining process, machining accuracy of part mainly depends on the position and orientation of the cutting tool with respect to the workpiece which is influenced by errors of machine tools and cutter-workpiece-fixture system. A systematic modeling method is presented to integrate the two types of error sources into the deviation of the cutting tool relative to the workpiece which determines the accuracy of the machining system. For the purpose of minimizing the machining error, an adjustment strategy of tool path is proposed on the basis of the generation principle of the cutter location source file (CLSF) in modern computer aided manufacturing (CAM) system by means of the prediction deviation, namely, the deviation of the cutting tool relative to the workpiece in computer numerical control (CNC) machining operation. The resulting errors are introduced as adjustment values to adjust the nominal tool path points from cutter location source file from commercial CAM system prior to machining. Finally, this paper demonstrates the effectiveness of the prediction model and the adjustment technique by two study cases.

scholarly journals Surface Roughness Prediction and Minimization in 5-Axis Milling Operations of Gas Turbine Blades

2021 ◽  
Author(s):  
Arameh Eyvazian ◽  
Farayi Musharavati ◽  
Afrasyab Khan ◽  
Mohsen Soori ◽  
Tamer A. Sebaey ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Gas Turbine ◽  
Turbine Blades ◽  
Machining Process ◽  
Machining Parameters ◽  
Gas Turbine Blades ◽  
Virtual Machining ◽  
Machined Parts ◽  
Machining System

Abstract To enhance the quality of machined parts, virtual machining systems are presented in this study. In the turbine blades, the minimization of the surface roughness of the blades can decrease the Reynolds number to decrease the loss of energy in power generation. Due to difficulties of polishing process in minimizing the surface roughness of machined blades, the optimized machining parameters for minimizing the surface roughness is an effective solution for the problem. In this study, a virtual machining system is developed to predict and minimize the surface roughness in 5-Axis machining operations of gas turbine blades. To minimize the surface roughness, the machining parameters were optimized by the Genetic algorithm. To validate the developed system, the turbine blades were machined using a 5-Axis CNC machine tool and the machined blades were measured using the CMM machine to obtain the surface roughness of machined parts. So, a 41.29% reduction in the measured surface roughness and a 42.09% reduction in the predicted surface roughness are obtained using the optimized machining parameters. The developed virtual machining system can be applied in the machining process of turbine blades to enhance the surface quality of machined blades and thus improve the efficiency of gas turbines.

scholarly journals A Composite Evaluation Model of Sustainable Manufacturing in Machining Process for Typical Machine Tools

Processes ◽  
2019 ◽  
Vol 7 (2) ◽  
pp. 110 ◽  
Author(s):  
Lishu Lv ◽  
Zhaohui Deng ◽  
Tao Liu ◽  
Linlin Wan ◽  
Wenliang Huang ◽  
...  
Keyword(s):  
Energy Efficiency ◽  
Machine Tools ◽  
Manufacturing Industry ◽  
Orthogonal Experiment ◽  
Evaluation Model ◽  
Sustainable Manufacturing ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Carbon Efficiency

Machine tool is the basic manufacturing equipment in today’s mechanical manufacturing industry. A considerable amount of energy and carbon emission are consumed in machining processes, the realization of sustainable manufacturing of machine tools have become an urgent problem to be solved in the field of industry and academia. Therefore, five types of machine tools were selected for the typical machining processes (turning, milling, planning, grinding and drilling). Then the model of the energy efficiency, carbon efficiency and green degree model were established in this paper which considers the theory and experiment with the resource, energy and emission modeling method. The head frame spindle and head frame box were selected to verify the feasibility and practicability of the proposed model, based on the orthogonal experiment case of the key machining process. In addition, the influence rules of machining parameters were explored and the energy efficiency and green degree of the machine tools were compared. Finally, the corresponding strategies for energy conservation and emission reduction were proposed.

Multiple performance characteristics optimization in end milling of thin-walled parts using desirability function

2020 ◽  
Vol 44 (1) ◽  
pp. 84-94 ◽  
Author(s):  
Djordje Cica ◽  
Stevo Borojevic ◽  
Goran Jotic ◽  
Branislav Sredanovic ◽  
Sasa Tesic
Keyword(s):  
Surface Roughness ◽  
Wall Thickness ◽  
End Milling ◽  
Influential Factor ◽  
Machining Process ◽  
Cnc Machine Tools ◽  
Reference Plane ◽  
Machining Parameters ◽  
Machining Strategy ◽  
Thin Walled

With the development of high-performance CNC machine tools, milling has been established as one of the main means of machining thin-walled parts. Thus, the selection of process parameters for milling operations is an important issue in end milling of thin-walled parts to assure product quality and increase productivity. The current study explores three machining parameters, namely wall thickness, feed, and machining strategies, that influence dimensional and form errors, surface roughness, and machining time milling of 7075-T6 aluminum alloy thin-walled parts. The effects of machining parameters on each of the response variables were analyzed using graphs of the main effects and three-dimensional surface plots. Analysis of the results show that the most influential factor for wall thickness deviation, dimensions deviation, perpendicularity deviation, flatness deviation, surface roughness of inner walls, surface roughness of outer walls, and surface roughness of reference plane was machining strategy, while feed is the most influential parameter affecting the machined time, followed by the machining strategy. The desirability concept has been used for simultaneous optimization in terms of machining parameters of the thin-walled parts machining process. Finally, a confirmation test with the optimal parameter settings was carried out to validate the results.

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.

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