scholarly journals THE EFFECT OF ALTERNATIVE CUTTER PATHS ON FLATNESS DEVIATIONS IN THE FACE MILLING OF ALUMINUM PLATE PARTS

2018 ◽  
Vol Vol.18 (No.1) ◽  
pp. 81-88 ◽  
Author(s):  
Michal DOBRZYNSKI ◽  
Daniel CHUCHALA ◽  
Kazimierz A. ORLOWSKI
Keyword(s):  
Manufacturing Process ◽  
Face Milling ◽  
Aluminum Plate ◽  
Piezoelectric Elements ◽  
The Face ◽  
Measuring Machine

In this paper the relationships between the alternative machining paths and flatness deviations of the aluminum plate part, were presented. The flatness tolerance of the main surface of the plate part has crucial meaning due to the assembly requirement of piezoelectric elements on the radiator. The aluminum bodies under investigation are the base part of the radiators with crimped feathers for the train industry. The surface of the aluminum plate part was milled using three different milling strategies: along of longer or shorter side of workpiece and at an angle of 45°. The aluminum bodies were machined on milling centre ecoMILL 70 DMG MORI. The flatness deviation measurements were carried out on the Coordinated Measuring Machine Altera 7.5.5 Nikon Metrology NV. These measurements were made during the manufacturing process of the radiator, namely after machining, however, before the process crimping of feathers. The results that were obtained enables the validation of assumed milling path strategies in connection of the subsequent machining and assembly processes.

scholarly journals Surface Roughness Evaluation in Thin EN AW-6086-T6 Alloy Plates after Face Milling Process with Different Strategies

Materials ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 3036
Author(s):  
Daniel Chuchala ◽  
Michal Dobrzynski ◽  
Danil Yurievich Pimenov ◽  
Kazimierz A. Orlowski ◽  
Grzegorz Krolczyk ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cold Rolling ◽  
Aluminium Alloy ◽  
Manufacturing Process ◽  
Thick Plate ◽  
Rolling Direction ◽  
Milling Process ◽  
Face Milling ◽  
Machining Process ◽  
The Face

Lightweight alloys made from aluminium are used to manufacture cars, trains and planes. The main parts most often manufactured from thin sheets requiring the use of milling in the manufacturing process are front panels for control systems, housing parts for electrical and electronic components. As a result of the final phase of the manufacturing process, cold rolling, residual stresses remain in the surface layers, which can influence the cutting processes carried out on these materials. The main aim of this study was to verify whether the strategy of removing the outer material layers of aluminium alloy sheets affects the surface roughness after the face milling process. EN AW-6082-T6 aluminium alloy thin plates with three different thicknesses and with two directions relative to the cold rolling process direction (longitudinal and transverse) were analysed. Three different strategies for removing the outer layers of the material by face milling were considered. Noticeable differences in surface roughness 2D and 3D parameters were found among all machining strategies and for both rolling directions, but these differences were not statistically significant. The lowest values of Ra = 0.34 µm were measured for the S#3 strategy, which asymmetrically removed material from both sides of the plate (main and back), for an 8-mm-thick plate in the transverse rolling direction. The highest values of Ra = 0.48 µm were measured for a 6-mm-thick plate milled with the S#2 strategy, which symmetrically removed material from both sides of the plate, in the longitudinal rolling direction. However, the position of the face cutter axis during the machining process was observed to have a significant effect on the surface roughness. A higher surface roughness was measured in the areas of the tool point transition from the up-milling direction to the down-milling direction (tool axis path) for all analysed strategies (Ra = 0.63–0.68 µm). The best values were obtained for the up-milling direction, but in the area of the smooth execution of the process (Ra = 0.26–0.29 µm), not in the area of the blade entry into the material. A similar relationship was obtained for analysed medians of the arithmetic mean height (Sa) and the root-mean-square height (Sq). However, in the case of the S#3 strategy, the spreads of results were the lowest.

Tool Wear Monitoring of Wiper Inserts in Multi-Insert Face Milling Using Three-Dimensional Surface Form Indicators

2015 ◽  
Vol 137 (3) ◽  
Author(s):  
Meng Wang ◽  
Te Ken ◽  
Shichang Du ◽  
Lifeng Xi
Keyword(s):  
Tool Wear ◽  
Three Dimensional ◽  
Face Milling ◽  
Surface Form ◽  
High Definition ◽  
3D Surface ◽  
Milled Surface ◽  
The Face ◽  
Measuring Machine ◽  
Occurrence Matrix

The wear of wiper inserts directly affects the finishing surface quality in multi-insert face milling. This research aims at monitoring the wear of wiper inserts, using 3D surface form as tool wear indicators. 3D surface height map of the face-milled surface is measured by a high definition metrology (HDM) instrument and converted into height-encoded and toolmark-straightened gray images. 3D surface form indicators, including entropy and contrast, are extracted from the converted images with a modified gray level co-occurrence matrix (GLCM) method. Meanwhile, the wear of wiper inserts is measured using a tool presetter and measuring machine without dismounting wiper inserts from the cutter. Experimental results indicate that entropy shows a strong correlation with average axial wear of the wiper edges and contrast reflects the evolution of axial offset between wiper inserts.

Material Selection for CFRP-Aluminium-Foam-Sandwiches Manufactured by a PUR Spraying Process

2017 ◽  
Vol 742 ◽  
pp. 317-324
Author(s):  
Peter Rupp ◽  
Peter Elsner ◽  
Kay André Weidenmann
Keyword(s):  
Manufacturing Process ◽  
Sandwich Structures ◽  
Bending Stiffness ◽  
Effective Density ◽  
Sandwich Composites ◽  
Open Cell ◽  
The Core ◽  
Bending Modulus ◽  
The Face ◽  
Spraying Process

Sandwich structures are ideal for planar parts which require a high bending stiffness ata low weight. Usually, sandwich structures are manufactured using a joining step, connecting theface sheets with the core. The PUR spraying process allows to include the infiltration of the facesheet fibres, the curing of the matrix and the joining of the face sheets to the core within one processstep. Furthermore, this manufacturing process allows for the use of open cell core structures withoutinfiltrating the core, which enables a comparison of different material configurations, assembled bythe same manufacturing process. The selection of these materials, with the aim of the lowest possiblemass of the sandwich composite at a constant bending stiffness, is displayed systematically within thiswork.It could be shown that the bending modulus calculated from the component properties matched theexperimentally achieved values well, with only few exceptions. The optimum of the bending modulus,the face sheet thickness and the resulting effective density could be calculated and also matched theexperimental values well. The mass-specific bending stiffness of the sandwich composites with corestructures of open cell aluminium foams was higher than with closed cell aluminium foams, but wasexceeded by sandwich composites with Nomex honeycomb cores.

Evaluation of Parts Produced by a Novel Additive Manufacturing Process

2013 ◽  
Vol 315 ◽  
pp. 63-67 ◽  
Author(s):  
Muhammad Fahad ◽  
Neil Hopkinson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
High Speed ◽  
Three Dimensional ◽  
Coordinate Measuring Machine ◽  
Layer By Layer ◽  
Nylon 12 ◽  
Measuring Machine ◽  
End Use

Rapid prototyping refers to building three dimensional parts in a tool-less, layer by layer manner using the CAD geometry of the part. Additive Manufacturing (AM) is the name given to the application of rapid prototyping technologies to produce functional, end use items. Since AM is relatively new area of manufacturing processes, various processes are being developed and analyzed for their performance (mainly speed and accuracy). This paper deals with the design of a new benchmark part to analyze the flatness of parts produced on High Speed Sintering (HSS) which is a novel Additive Manufacturing process and is currently being developed at Loughborough University. The designed benchmark part comprised of various features such as cubes, holes, cylinders, spheres and cones on a flat base and the build material used for these parts was nylon 12 powder. Flatness and curvature of the base of these parts were measured using a coordinate measuring machine (CMM) and the results are discussed in relation to the operating parameters of the process.The result show changes in the flatness of part with the depth of part in the bed which is attributed to the thermal gradient within the build envelope during build.

scholarly journals Simulating the effect of depth of cut and feed rate on the force components in face milling

2019 ◽  
Vol 9 (1) ◽  
pp. 65-72
Author(s):  
Mohammad Zaher Akkad ◽  
Felhő Csaba
Keyword(s):  
Feed Rate ◽  
Face Milling ◽  
Depth Of Cut ◽  
Third Wave ◽  
Cutting Depth ◽  
Milling Operation ◽  
The Face ◽  
Force Components ◽  
Cutting Processes ◽  
The Impact

This paper presents a study about the workpiece force components (Fx, Fy, Fz) changes in face milling, which results from changing the depth of cut and the feed rate values. The values of the three force components in the face milling operation were found through the FEA-software AdvantEdge by Third Wave Systems. This program is uniquely intended for modelling of cutting processes. Simulations were carried out within five different cutting depth of cut and feed rate, to compare the obtained values and find out the results of the impact of changes on the three force components.

Improved accuracy of an FDM 3D printer using a face-diagonal length test using an artifact and a Vernier caliper

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Seung-Han Yang ◽  
Kwang-Il Lee
Keyword(s):  
Fused Deposition Modeling ◽  
3D Printer ◽  
Geometric Errors ◽  
Content Type ◽  
Fused Deposition ◽  
Model Based ◽  
The Face ◽  
Deposition Modeling ◽  
Measuring Machine ◽  
Diagonal Length

Purpose The purpose of this study is to improve the accuracy of a fused deposition modeling three-dimensional (3D) printer by identifying and compensating for position-independent geometric errors using a face-diagonal length test featuring a designed artifact and a Vernier caliper. Design/methodology/approach An artifact that does not require support when printing was designed and printed to allow performance of the face-diagonal length test. A Vernier caliper was used to measure the lengths of diagonals in the XY, YZ and ZX planes of the printed artifact specimen; this completed the face-diagonal length test. The relationships between position-independent geometric errors of the linear axes X, Y and Z and the measured diagonal lengths of the three planes were determined to identify geometric errors. Findings The approach was applied to a commercial fused deposition modeling 3D printer, and three position-independent geometric errors were rapidly identified. The artifact was re-printed after model-based compensation for these errors and the diagonal lengths were re-measured. The results were verified via coordinate measuring machine measurement of a simple test piece without and with model-based compensation for identified geometric errors. Furthermore, the proposed approach was applied to a commercial 3D printer. Research limitations/implications The measured diagonal lengths of the printed artifacts varied greatly. Thus, further studies should investigate the effects of printing materials and parameters on the length discrepancies of 3D printed artifacts. Practical implications A software-based compensation of identified position-independent geometric errors has to be used at commercial 3D printers for accuracy improvements of printed parts. Originality/value Thus, the approach is of practical utility; it can be periodically used to identify position-independent geometric errors and ensure that the 3D printer is consistently accurate.

Effect of Cutting Speed on the Face Milling of CFRP Using a PCD Tool

2016 ◽  
Vol 874 ◽  
pp. 487-491
Author(s):  
Takayuki Kitajima ◽  
Takumi Horiuchi ◽  
Akinori Yui ◽  
Yosuke Ito
Keyword(s):  
Mechanical Characteristics ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Face Milling ◽  
Fiber Reinforced Plastic ◽  
Pcd Tool ◽  
Reinforced Plastic ◽  
The Face ◽  
Cutting Speeds

Carbon-fiber-reinforced plastic (CFRP) is used in various industries such as aerospace and automobile industries because of its high mechanical characteristics. However, this material is difficult to cut. Tool wear and delamination frequently occur during the drilling or cutting of CFRP. In previous studies, we developed a CFRP cutting tool using polycrystalline diamond (PCD). The PCD tool exhibited excellent cutting performance at cutting speeds as low as <120 m/min. In this study, the authors investigated the effect of cutting speed on the face milling of CFRP by using the developed PCD tool.

scholarly journals Research and Optimization of Surface Roughness in Milling of SLM Semi-Finished Parts Manufactured by Using the Different Laser Scanning Speed

Materials ◽  
2019 ◽  
Vol 13 (1) ◽  
pp. 9 ◽  
Author(s):  
Andrzej Matras
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Laser Scanning ◽  
Cutting Tool ◽  
Scanning Speed ◽  
Milling Process ◽  
Face Milling ◽  
Machining Parameters ◽  
The Face ◽  
Laser Scanning Speed

The paper studies the potential to improve the surface roughness in parts manufactured in the Selective Laser Melting (SLM) process by using additional milling. The studied process was machining of samples made of the AlSi10Mg alloy powder. The simultaneous impacts of the laser scanning speed of the SLM process and the machining parameters of the milling process (such as the feed rate and milling width) on the surface roughness were analyzed. A mathematical model was created as a basis for optimizing the parameters of the studied processes and for selecting the sets of optimum solutions. As a result of the research, surface with low roughness (Ra = 0.14 μm, Rz = 1.1 μm) was obtained after the face milling. The performed milling allowed to reduce more than 20-fold the roughness of the SLM sample surfaces. The feed rate and the cutting width increase resulted in the surface roughness deterioration. Some milled surfaces were damaged by the chip adjoining to the rake face of the cutting tool back tooth.

scholarly journals FPGA Based Real Time Simulations of the Face Milling Process

IEEE Access ◽  
2020 ◽  
Vol 8 ◽  
pp. 215987-216002
Author(s):  
Michal R. Mazur ◽  
Marek A. Galewski ◽  
Krzysztof J. Kalinski
Keyword(s):  
Real Time ◽  
Milling Process ◽  
Face Milling ◽  
The Face ◽  
Real Time Simulations
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