GPGPU-based Material Removal Simulation and Cutting Force Estimation

2010 ◽  
Author(s):  
B. Tukora ◽  
T. Szalay
Keyword(s):  
Cutting Force ◽  
Material Removal ◽  
Force Estimation

Cutting Path Design to Minimize Workpiece Displacement at Cutting Point: Milling of Thin-Walled Parts

2012 ◽  
Vol 6 (5) ◽  
pp. 638-647 ◽  
Author(s):  
Yusuke Koike ◽  
◽  
Atsushi Matsubara ◽  
Shinji Nishiwaki ◽  
Kazuhiro Izui ◽  
...  
Keyword(s):  
Cutting Force ◽  
Material Removal ◽  
Tool Orientation ◽  
Numerical Example ◽  
Path Design ◽  
Minimum Displacement ◽  
Low Stiffness ◽  
Thin Walled ◽  
Cutting Path ◽  
Cutting Point

Vibrations of a tool or workpiece during cutting operations shorten tool life and causes unwanted surface roughness. In this report, we propose an algorithm for determining the sequence of material removal, tool orientation, and feed directions, an algorithm minimizes workpiece displacements by considering workpiece stiffness and cutting force. In this research, the cutting path consists of the material removal sequence, tool orientation and feed directions. The material removal sequence changes the workpiece compliancematrix at the cutting points, and the feed directions and tool orientation change the direction of the cutting force. In our algorithm, workpiece displacements are reduced by changing the material removal sequence and applying the cutting force in the direction of higher workpiece stiffness. A numerical example demonstrates how the algorithm obtains appropriate cutting paths to mill a cantilever form. In the numerical example, three optimized cutting paths are compared with an unoptimized cutting path, a path used by an expert and based on the expert’s personal experience, to machine a low-stiffness workpiece. The obtained material removal sequence of the minimax compliance path is almost the same as that of the unoptimized cutting path. Workpiece displacements at the cutting point of three optimized cutting paths are approximately 10% smaller than those of the unoptimized cutting path. The minimum displacement path is the best of these three optimized cutting paths because fluctuations in workpiece displacements at cutting point are the smallest. These optimized cutting paths show the cutting path strategy as a rough cutting path for machining the thin-walled cantilever.

Cutting Force Analysis of on-Machine Fabricated PCD Tool during Glass Micro-Grinding

2011 ◽  
Vol 264-265 ◽  
pp. 1085-1090 ◽  
Author(s):  
Asma Perveen ◽  
Muhammad Pervej Jahan ◽  
Yoke San Wong ◽  
Mustafizur Rahman
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Material Removal ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Hard Materials ◽  
Pcd Tool ◽  
Fluidic Devices ◽  
Micro Machine ◽  
Poly Crystalline Diamond

Brittle and hard materials are problematic to mechanically micro machine due to damage resulting from material removal by brittle fracture, cutting force-induced tool deflection or breakage and tool wear. As a result, the forces arising from the cutting process are important parameter for material removal. This study was undertaken to investigate the effect of cutting conditions on cutting forces and the machined surface during the glass micro grinding using on-machine fabricated (Poly Crystalline Diamond) PCD tool. Experimental results showed that an increase in depth of cut and feed rate can result in increase of cutting forces and surface roughness as well. Among the forces in 3 axes, force along feed direction is found to be larger, which played a major role in material removal. Finally, it is observed that PCD tool exhibits promising behaviour to machine brittle material like BK-7 glass for producing micro molds and micro fluidic devices, since it has better wear resistance, experiences less cutting forces and generates smooth surfaces with Ra value of as low as 12.79 nm.

Research on Microscopic Grain-Workpiece Interaction in Grinding through Micro-Cutting Simulation, Part 2: Factorial Study

2009 ◽  
Vol 76-78 ◽  
pp. 15-20 ◽  
Author(s):  
Lan Yan ◽  
Xue Kun Li ◽  
Feng Jiang ◽  
Zhi Xiong Zhou ◽  
Yi Ming Rong
Keyword(s):  
Cutting Force ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Shear Angle ◽  
Depth Of Cut ◽  
Specific Cutting Force ◽  
Single Grain

The grinding process can be considered as micro-cutting processes with irregular abrasive grains on the surface of grinding wheel. Single grain cutting simulation of AISI D2 steel with a wide range of cutting parameters is carried out with AdvantEdgeTM. The effect of cutting parameters on cutting force, chip formation, material removal rate, and derived parameters such as the specific cutting force, critical depth of cut and shear angle is analyzed. The formation of chip, side burr and side flow is observed in the cutting zone. Material removal rate increases with the increase of depth of cut and cutting speed. Specific cutting force decreases with the increase of depth of cut resulting in size effect. The shear angle increases as the depth of cut and cutting speed increase. This factorial analysis of single grain cutting is adopted to facilitate the calculation of force consumption for each single abrasive grain in the grinding zone.

scholarly journals Efficiency increase in profile deep grinding of turbine blade on NC multi-axes machines

2018 ◽  
Vol 2018 (4) ◽  
pp. 21-29
Author(s):  
Владимир Макаров ◽  
Vladimir Makarov ◽  
Сергей Никитин ◽  
Sergey Nikitin
Keyword(s):  
Cutting Force ◽  
Turbine Blade ◽  
Fatigue Resistance ◽  
Material Removal ◽  
Surface Profile ◽  
Dynamic Processes ◽  
Efficiency Increase ◽  
Deep Profile ◽  
Cutting Modes ◽  
Elementary Area

The paper reports the procedure of a cutting mode purpose at deep profile grinding on NC multi-axes machines on the basis of the modeling of thermo-dynamic processes in cutting areas with the purpose of ensuring turbine blade fatigue resistance. There are shown simulators allowing the definition and prediction of the dynamics of elastic, thermal and working processes in a technological system, material removal, cutting force, temperatures in the area of cutting and roughness of each elementary area of the surface profile on the basis of cutting modes, disk characteristics.

Precise Cutting Force Estimation by Hybrid Estimation of DC/AC Components

2020 ◽  
Author(s):  
Taiki Sato ◽  
Shuntaro Yamato ◽  
Yasuhiro Imabeppu ◽  
Naruhiro Irino ◽  
Yasuhiro Kakinuma
Keyword(s):  
Cutting Force ◽  
Thrust Force ◽  
End Milling ◽  
Moving Average ◽  
Low Frequency ◽  
Friction Model ◽  
Ball Screw ◽  
Estimation Accuracy ◽  
Force Estimation ◽  
Feed Direction

Abstract External sensor-less cutting force estimation using a load-side disturbance observer (LDOB) has potential to estimate the cutting force with high accuracy in both feed and cross-feed directions. However, the accuracy of its low frequency components in feed direction decrease due to effect of the friction and heat of a ball-screw-driven stage. In this study, DC and AC components of the cutting force is estimated by different methods; friction-compensated motor thrust force and LDOB, and the cutting force was estimated in real time by hybridizing them. In particular, regarding the friction model, the dynamic and static characteristics of the friction force in each axis (X, Y, Z) were identified from the idling test results. In addition to the model that depends on the velocity, the characteristics of the friction that depend on the position was also identified and considered when compensating for the motor thrust force. Then, a simple moving average filter with an appropriate window length is applied to the cutting force by LDOB and motor thrust force, and the DC component error of LDOB is corrected by that of motor thrust force. The validity of the proposed method was evaluated through end-milling tests. The experimental results showed that estimation accuracy of cutting force using the proposed method can be greatly improved in feed directions. On the other hand, in cross-feed direction, the cutting estimation was performed using the conventional LDOB.

scholarly journals Enhancement of Sensor-less Cutting Force Estimation by Tuning of Observer Parameters from Cutting Test

2019 ◽  
Vol 41 ◽  
pp. 272-279
Author(s):  
Shuntaro Yamato ◽  
Yasuhiro Imabeppu ◽  
Naruhiro Irino ◽  
Norikazu Suzuki ◽  
Yasuhiro Kakinuma
Keyword(s):  
Cutting Force ◽  
Force Estimation ◽  
Cutting Test

Comparison of Material Removal Characteristics in Single and Multiple Cutting Edge Scratches

2013 ◽  
Vol 797 ◽  
pp. 189-195 ◽  
Author(s):  
Xun Chen ◽  
Tahsin Tecelli Öpöz
Keyword(s):  
Cutting Force ◽  
Specific Energy ◽  
Material Removal ◽  
Experimental Results ◽  
Multiple Edge ◽  
Test Material ◽  
Grinding Process ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Single Edge

This paper presents the important characteristics of material removal mechanism during single grit scratching test. Material removal mechanism in these scratches shows cutting and ploughing action varies with the number of cutting edges leading to different cutting force and specific energy. According to experimental results, single edge scratches are more efficient cutting while multiple edge scratches give more ploughing actions, which consume energy with little contribution to materials removal. The results provided an important insight of material removal during grinding process.

Sensorless Cutting Force Monitoring Using Parallel Disturbance Observer

2009 ◽  
Vol 3 (4) ◽  
pp. 415-421 ◽  
Author(s):  
Daisuke Kurihara ◽  
◽  
Yasuhiro Kakinuma ◽  
Seiichiro Katsura ◽  
Keyword(s):  
Robust Control ◽  
Cutting Force ◽  
Disturbance Observer ◽  
Force Sensor ◽  
Force Estimation ◽  
Machining Processes ◽  
Current Reference ◽  
Velocity Response ◽  
Force Monitoring

Measuring cutting force is effective in monitoring machining processes, but requires that a force sensor be installed on the tool table. The parallel disturbance observer we propose in table control using velocity response and current reference realizes both robust control and cutting force estimation without additional sensors. Performance of this method was evaluated through simulation and experiments.

Sign in / Sign up

Export Citation Format

Share Document