Ruled Surface Machining on Five-Axis CNC Machine Tools

To achieve high precision and high productivity in machining sculptured surfaces, a new architecture for a five-axis CNC interpolator for machining ruled surfaces was developed and demonstrated on a milling machine. The objective of the five-axis interpolator is to continuously maintain the milling cutter axis in parallel with the straight lines of the ruled surface. The cutter position and orientation are calculated at each sampling period of the interpolator, and corresponding axial position commands are generated by an inverse kinematics algorithm. This real-time approach produces precise surfaces and requires substantially less machining time compared to the conventional off-line approach. Two new g-codes are also given in this paper for the new interpolator to produce part surfaces in CNC milling machines.     

Micro dimple milling on cylinder surfaces

The paper presents a micro dimple machining on a cylinder surface with a two-flutes ball end mill. When the cutter axis is inclined and the depth of cut is less than the tool radius, non-cutting time, during which neither of the two cutting edges contacts the workpiece, appears in a rotation of the cutter. The rotation of the workpiece and the feed of the tool are controlled so that the cutting areas do not overlap each other. In order to incline the tool with respect to the tangential direction on the cylinder surface, the tool is located at a position oriented at 45° from the top of the cylinder. An analytical model is presented to control the shapes of the dimples with the cutting parameters. The presented machining is verified in cutting tests with measuring the shape and the profile of the dimples. Pre-machining operations are conducted to have a high cylindricity of the workpiece in longitudinal turning and polishing. The cutter runout of the tool is also eliminated by adjusting the orientation and the position of the tool in the collet chuck with measuring the cutting force. The micro dimples are machined accurately as they are simulated.     

Analysis of machined surface quality in a single-pass of ball-end milling on Inconel 718

The ball-end milling process is widely used for generating three-dimensional sculptured surfaces with definite curvature. In such cases, variation of surface properties along the machined surface curvatures is not well understood. Therefore, this paper reports the effect of machining parameters on the quality of surface obtained in a single-pass of a ball-end milling cutter with varying chip cross-sectional area. This situation is analogous to generation of free form cavities, pockets, and round fillets on mould surfaces. The machined surfaces show formation of distinct bands as a function of instantaneous machining parameters along the periphery of cutting tool edge, chip compression and instantaneous shear angle. A distinct variation is also observed in the measured values of surface roughness and micro-hardness in these regions. The maximum surface roughness is observed near the tool tip region on the machined surface. The minimum surface roughness is obtained in the stable cutting zone and it increases towards the periphery of the cutter. Similar segmentation was observed on the deformed chips, which could be correlated with the width of bands on the machined surfaces. The sub-surface quality analysis in terms of micro-hardness helped define machining affected zone (MAZ). The parametric effects on the machining induced shear and residual stresses have also been evaluated.     

An Approach to Theoretical Modeling and Simulation of Face Milling Forces

A new approach to theoretical modeling and simulation of face milling forces is presented. The present approach is based on a predictive machining theory in which machining characteristic factors in continuous cutting with a single-point cutting tool can be predicted from the workpiece material properties, tool geometry, and cutting conditions. The action of a milling cutter is considered as the simultaneous work of a number of single-point cutting tools, and the milling forces are predicted from input data of workpiece material properties, cutter parameters and tooth geometry, cutting condition, cutter and workpiece vibration structure parameters, and types of milling. A predictive force model for face milling is developed using this approach. In the model, the workpiece material properties are considered as functions of strain, strain rate, and temperature. The ratio of cutter tooth engagement over milling is taken into account for the determination of temperature in the cutting region. Cutter runout is included in the modeling for the chip load. The relative displacement between the cutter and workpiece due to the cutter and workpiece vibration is also included in the modeling to consider the effect on the undeformed chip thickness. A milling force simulation system has been developed using the model, and face milling experimental tests have been conducted to verify the simulation system. It is shown that the simulation results agree well with experimental results.     

Experimental Evaluation of Cutter Orientation When Ball Nose End Milling Inconel 718™

High-speed machining (HSM), specifically end milling and ball end cutting, is attracting interest in the aerospace industry for the machining of complex 3D aerofoil surfaces in titanium alloys and nickel-based superalloys. Following a brief introduction on HSM and related aerospace work, the paper reviews published data on the effect of cutter/workpiece orientation, also known as engagement or tilt angle, on tool performance. Such angles are defined as ±β_fN and ±β_f.Experimental work is detailed on the effect of cutter orientation on tool life, cutting forces, chip formation, specific force, and workpiece surface roughness when high-speed ball end milling Inconel 718™. Dry cutting was performed using 8 mm diameter PVD-coated solid carbide cutters with the workpiece mounted at an angle of 45° from the cutter axis.A horizontal downward (-β_fN) cutting orientation provided the best tool life with cut lengths ∼50% longer than for all other directions (+β_fN, +β_f, and –β_f). Evaluation of cutting forces and associated spectrum analysis of results indicated that cutters employed in a horizontal downward direction produced the least vibration. This contributed to improved workpiece surface roughness, with typical mean values of ∼0.4 μm Ra as opposed to ∼1.25 μm Ra when machining in the vertical downward (–β_f) direction.     

AlCrSiN/AlCrN/AlCrON/AlCrN多层复合涂层的研究

目的 解决硬质合金刀具高速干切削难加工材料面临效率低、寿命短的难题,提升刀具涂层的耐热能力,在AlCrSiN涂层中周期性植入AlCrON热屏障层,并在其两侧沉积AlCrN层进行包夹,改善含氧层的韧性,既能保持涂层刀具较高的强度,又能改善其耐热能力.方法 采用全自动电弧离子镀膜机,研制具有不同调制周期的AlCrSiN/A...     

Evaluating the use phase energy requirements of a machine tool system

This paper has an energy consumption reduction perspective by considering alternative machining strategies and system components interactions translated into variable and constant power flows with respect to various use phase regimes of a machine tool system. The methodology is able to estimate the mechanical energy requirements of the spindle and feed axes with respect to 2.5D machining strategies by taking into account steady-state and transient regimes. In addition, the specific amount of fixed energy drawn by a machine was determined based on a careful monitoring of the energy share amongst the auxiliary equipment that supports the accomplishment of the machining tasks. The numerical results were experimentally validated and the good agreement between them led to the conclusion that the proposed methodology can be used effectively for the calculation of the total energy required by a machine tool system for the milling of a part. This enables a straightforward comparison of different milling part programs with respect to their energy consumption levels.     

Machining assessment of nano-crystalline hydroxyapatite bio-ceramic

Hydroxyapatite (HAP) is a widely used bio-ceramic in the fields of orthopedics and dentistry. This study investigates the machinability of nano-crystalline HAP (nHAP) bio-ceramic in end milling operations, using uncoated carbide tool under dry cutting conditions. Efforts are focused on the effects of various machining conditions on surface integrity. A first order surface roughness model for the end milling of nHAP was developed using response surface methodology (RSM), relating surface roughness to the cutting parameters: cutting speed, feed, and depth of cut. Model analysis showed that all three cutting parameters have significant effect on surface roughness. However, the current model has limited statistical predictive power and a higher order model is desired. Furthermore, tool wear and chip morphology was studied. Machined surface analysis showed that the surface integrity was good, and material removal was caused by brittle fracture without plastic flow.     

Micro end mill tool temperature measurement and prediction

The objective of this work is to characterize the heat transfer in micro end mill tools during machining operations. This analysis will aid in the design of heat dissipation strategies that could potentially increase tool life and machining precision. Tool temperatures, above the unmachined workpiece surface, have been measured using an infrared camera during slot milling of aluminum (6061-T6) and steel (1018) with 300 μm-diameter two-flute tungsten carbide end mills. The measured temperatures compare favorably with temperature distributions predicted by a two-dimensional, transient, heat transfer model of the tool. The heat input is estimated by applying Loewen and Shaw’s heat partitioning analysis. Analysis of heat transfer in the tool found that 46 s into a cut conduction through the length of the tool, storage in the tool, and convection from the surface account for 41.5%, 45%, and 13.5% of the heat generated during machining. Thermal expansion and cooling strategies are discussed.     

An experimental investigation into micro ball end-milling of silicon

Silicon is a representative operational material for semiconductor and micro-electronics. In certain MEMS applications, it is required to fabricate three dimensional channels and complex pattern on silicon substrate. Such features are typically fabricated by photolithography and chemical etching. These processes have low productivity and have certain other limitations. Therefore, a viable switch-over from non-traditional fabrication processes to traditional machining is highly desired for improved productivity in high-mix low-volume production. However, machining of silicon by traditional process is extremely difficult due to its high brittleness. Even very small forces produced during machining can cause brittle fracture on silicon surface resulting in deteriorated surface quality. The fundamental principle in machining of a brittle material such as silicon is to achieve material removal through plastic deformation rather than crack propagation. This paper presents the experimental results of ductile-mode machining of silicon by micro ball end-milling. The workpiece surface was inclined to the rotational axes of the cutter to improve the surface finish. It was established experimentally that 15-μm deep, fracture-free slots can be machined on silicon wafer by micro ball end-milling if the feed rate is below a certain threshold. The influence of several machining parameters on the roughness of machined-surface was also investigated. Cubic boron nitride (CBN) is presented as much economical alternative tool-material to single-crystal diamond for machining silicon in ductile-mode.     

Ball end milling mechanistic model based on a voxel-based geometric representation and a ray casting technique

Prediction of machining forces involved in complex geometry can be valuable information for machine shops. This paper presents a mechanistic cutting force simulation model for ball end milling processes, using ray casting and voxel representation methods used in 3D computer graphics field. Using this method, instantaneous uncut chip cross sectional areas can be extracted, which can be used in cutting pressure coefficient extraction and machining simulation including machining forces and geometry of the workpiece. The major advantage of the proposed scheme is that it can simulate milling processes with arbitrary cutting tool geometry on a workpiece with complex geometry, using an algorithm with constant time complexity. A series of cutting experiments were carried out to validate the model.     

铣削工艺参数对锡铋合金表面粗糙度特征影响及试验分析

目的对锡铋合金表面粗糙度特征进行研究分析,提高表面加工质量。方法采用正交试验设计方法,以最小表面粗糙度作为优化指标,以主轴转速、铣削深度、进给速度、铣削宽度作为影响因素,进行精密铣削试验研究。结果利用方差分析确定了进给速度是锡铋合金铣削表面粗糙度最重要的影响因素,并基于田口方法优化分析得到了锡铋合金铣削加工工艺最优组合。结论采用田口法对锡铋合金铣削工艺参数优化,有效地减少了加工表面粗糙度,提高了工件表面质量。     

Estimation of Maximum Allowable Step Length for Five-Axis Cylindrical Machining

Five-axis cylindrical machining is the only way to machine some complicated sculptured surfaces, such as the wheel surfaces of turbo compressors. Current computer-aided manufacturing (CAM) algorithms for five-axis cylindrical machining only consider the surfaces’ geometric information when generating cutter contact points (CC points). Hence, the step length, which is the distance between two CC points, is determined only by the surface parameters for these CAM algorithms. Because of tool-axis rotation, the actual cut trajectory within each step is no longer a straight line passing through two consecutive CC points for five-axis machining. Thus the cut error and the maximum allowable step length should depend on the structural parameters of NC machines as well as the surface's geometry. This paper develops a new algorithm to estimate the maximum allowable step length based on the cut error of five-axis cylindrical machining, and shows that this algorithm provides better estimation than traditional algorithms.     

Surface roughness prediction in milling based on tool displacements

In this paper, an experimental device using non-contact displacement sensors for the investigation of milling tool behaviour is presented. It enables the recording of high frequency tool vibrations during milling operations. The aim of this study is related to the surface topography prediction using tool displacements and based on tool center point methodology. From the recorded signals and the machining parameters, the tool deformation is modeled. Then, from the calculated deflection, the surface topography in 3D can be predicted. In recent studies, displacements in XY plane have been measured to predict the surface topography in flank milling. In this article, the angular deflection of the tool is also considered. This leads to the prediction of surfaces obtained in flank milling as well as in end milling operations. Validation tests were carried out: the predicted profiles were compared to the measured profile. The results show that the prediction corresponds well in shape and amplitude with the measurement.     

Evaluation of near-dry machining effects on gear milling process efficiency

One of the main environmental pollution sources related to machine building industry is the huge amount of cutting fluids which are supplied during the machining processes. In order to avoid the problems induced by cutting fluids' usage, considerable progress has been recently made in the field of near-dry machining (NDM). Converting conventional processes to minimal quantity lubrication (MQL) methods imposes new tasks' classification within the tribiological system in order to guarantee the process safety and product quality. This paper gives an overview on some requirements to be considered for a successful MQL application into industrial practice. Its last part is focused on the evaluation of NDM effects on the gear milling process efficiency, with respect to hob wear, surface quality, cooling effect, and environment protection.     

Analytical modelling of residual stresses in orthogonal machining of AISI4340 steel

Residual stress profile in a component is often considered as the critical characteristic as it directly affects the fatigue life of a machined component. This work presents an analytical model for the prediction of residual stresses in orthogonal machining of AISI4340 steel. The novelty of the model lies in the physics-based approach focusing on the nature of contact stresses in various machining zones and the effect of machining temperature. The model incorporates: (i) stresses in three contact regions viz. shear, tool-nose-work piece and tool flank and machined surface, (ii) machining temperature, (iii) strain, strain rate and temperature dependent work material properties, (iv) plastic stresses evaluation by two algorithms, S-J and hybrid, (v) relaxation procedure and (iv) cutting conditions. The model benchmarking shows (86–88%) agreement between the experimental and predicted residual stresses in the X- and Y-directions. On the machined surface, the tensile residual stresses decrease with an increase the edge radius and increase with an increase the cutting speed. However, below the surface, the compressive residual stresses increase with an increase the depth of cut. Further, it is observed that the proposed model with hybrid algorithm gives better results at a lower feed rate, whereas with the S-J algorithm, at a higher feed rate.     

Evaluation of vegetable based cutting fluids with extreme pressure and cutting parameters in turning of AISI 304L by Taguchi method

Many problems such as health and environment issues are identified with the use of cutting fluids (CFs). There has been a high demand for developing new environmentally friendly CFs such as vegetable based cutting fluids (VBCFs) to reduce these harmful effects. In this study, performances of six CFs, four different VBCFs from sunflower and canola oils with different ratios of extreme pressure (EP) additives, and two commercial types of CFs (semi-synthetic and mineral) are evaluated for reducing of surface roughness, and cutting and feed forces during turning of AISI 304L austenitic stainless steel with carbide insert tool. Taguchi’s mixed level parameter design (L₁₈) is used for the experimental design. Cutting fluid, spindle speed, feed rate and depth of cut are considered as machining parameters. Regression analyses are applied to predict surface roughness, and cutting and feed forces. ANOVA is used to determine effects of the machining parameters and CFs on surface roughness, cutting and feed forces. In turning of AISI 304L, effects of feed rate and depth of cut are found to be more effective than CFs and spindle speed on reducing forces and improving the surface finish. Performances of VBCFs and commercial CFs are also compared and results generally show that sunflower and canola based CFs perform better than the others.     

荧光灯管芯柱玻璃中金属铅的机械化学硫化

以硫化钠为硫化剂,机械化学硫化荧光灯管芯柱玻璃中金属铅,实现金属铅向硫化铅快速转化.通过单因素实验,考察了不同机械化学硫化条件,即球磨时间、球磨转速和球料比对硫化率的影响,并通过XRD、SEM和粒度对硫化产物进行表征.结果表明,硫化率随球磨时间和球磨转速的增大而增大,随球料比的增大先增大后减小,当球磨转速为750r/min、球磨时间为120min、球料比为50：1g/g时,荧光灯管芯柱玻璃中金属铅的硫化率可达96.18%.XRD结果表明,荧光灯管芯柱玻璃中金属铅的机械化学硫化产物为PbS、SEM和粒度结果表明,荧光灯管芯柱玻璃的粒径随球磨转速和球磨时间的增加而减小.     

Robust prediction of chatter stability in milling based on the analytical chatter stability

A major obstacle that limits the productivity in machining operations is the presence of machine tool chatter. Machining is a dynamic process and chatter behavior depends upon a number of different aspects including spindle speeds, material properties, tool geometry, and even the location of tool respect to the rest of machine. Many of the traditional models used to predict chatter stability lobes assume that parameters such as natural frequency, stiffness, and cutting coefficients remain constant. In reality, these parameters vary and they affect the chatter stability. The uncertainty in these parameters can be taken into consideration by employing the robust stability theory into a two degree of freedom milling model. Utilizing the Edge theorem and the Zero Exclusion condition, a robust chatter stability model, based on the analytical chatter stability milling model, is developed. This improves the reliability compared to the projected pseudo single degree of freedom model. The method is verified experimentally for milling operations while considering a changing natural frequency and cutting coefficient.     

模具制造中曲面与型体的形成和加工

阐述了在模具制造中 ,如何应用CAD/CAM系统来形成曲面和模型 ,并自动生成刀具轨迹 ,提高模具制造质量和效率