Tool trajectory generation based on tool deflection effects in the flat-end milling process (II) —Prediction and compensation of milled surface errors—

1999 ◽  
Vol 13 (12) ◽  
pp. 918-930 ◽  
Author(s):  
Tae-Il Seo ◽  
Myeong-Woo Cho
Keyword(s):  
End Milling ◽  
Trajectory Generation ◽  
Milling Process ◽  
Tool Deflection ◽  
Surface Errors ◽  
Milled Surface ◽  
Tool Trajectory ◽  
Flat End Milling ◽  
End Milling Process

A Tool Deflection Compensation System for End Milling Accuracy Improvement

1998 ◽  
Vol 120 (2) ◽  
pp. 222-229 ◽  
Author(s):  
M. Y. Yang ◽  
J. G. Choi
Keyword(s):  
Feed Rate ◽  
Cutting Forces ◽  
End Milling ◽  
Dimensional Accuracy ◽  
Milling Process ◽  
Compensation System ◽  
Experimental Investigations ◽  
Tool Deflection ◽  
Surface Errors ◽  
Tool Deflections

In an effort to reduce machining surface errors due to tool deflection in the end milling process, methods regulating cutting forces have been implemented with online feed rate controls. Such schemes are able to improve the parts dimensional accuracy, but unfortunately they can exhibit undesirable aspects in which the alleviation of the cutting conditions deteriorates the productivity. In addition the frequent changes of the feed rate would spoil the surface quality. As a new approach to achieve the precision machining efficiently, this paper introduces a tool deflection compensation system. This compensation system is a computer controlled special tool adapter which is capable of measuring the cutting forces and minutely adjusting the position of the tool without interfacing with the NC controller of the milling machine. Such a system allows for on-line estimation of the tool deflections and reduction of the surface errors. Experimental investigations for typical shaped workpieces representing various end milling situations are performed to verify the ability of the system to suppress the surface errors due to tool deflections in more productive machining condition.

Modeling and Simulation of Surface Texture for End-Milling Process

2017 ◽  
pp. 19-39
Author(s):  
Manoj Kumar
Keyword(s):  
Surface Roughness ◽  
End Milling ◽  
Milling Process ◽  
Simulation Software ◽  
Computational Algorithms ◽  
Roughness Parameters ◽  
Surface Errors ◽  
Surface Location ◽  
Computer Resources ◽  
End Milling Process

Analysis and simulation of manufacturing process require extensive and complicated computations. Nowadays, computer resources and computational algorithms reach to the state that can model and simulate the problem efficiently. One of the important processes in manufacturing is machining. In this research end-milling process which is one of the complex and wide-spread processes in machining is chosen. Most important parameters in end-milling are surface roughness and surface location errors. A comprehensive simulation software is developed to model end-milling process in order to anticipate finishing parameter such as surface roughness and errors. The proposed algorithm takes into account cutting conditions, such as feed, doc, woc, tool run out, etc. In addition, dynamic simulation module of the software can accurately model flexible end-mill tool, the milling cutting forces and regeneration of waviness effects. The software can accurately determine the most commonly used index of surface roughness parameters such as Ra, P.T.V. and surface errors.

A New Method for Identifying the Cutter Runout Parameters in Flat End Milling Process

2011 ◽  
Vol 697-698 ◽  
pp. 71-74 ◽  
Author(s):  
Min Wan ◽  
M.S. Lu ◽  
Wei Hong Zhang ◽  
Y. Yang ◽  
Y. Li
Keyword(s):  
End Milling ◽  
Chip Thickness ◽  
Least Square Method ◽  
Noise Signal ◽  
Milling Process ◽  
Least Square ◽  
Cutter Runout ◽  
Flat End Milling ◽  
Instantaneous Uncut Chip Thickness ◽  
End Milling Process

Cutter runout will redistribute the instantaneous uncut chip thickness and the cutting forces in multi-fluted milling process. In this paper, a new procedure is proposed to identify the cutter runout parameters for flat end milling process. By combining least-square method, mathematical derivations and implementation procedures are carried out based on the relative deviation between each cutting edge and the spindle rotation center, measured by a dial gauge. Numerical verifications are conducted to validate the proposed procedures, and the results show that they are efficient and reliable. It is also suggested that to weaken the influence of noise signal, measurements should be conducted at multiple axial positions.

The Prediction of Surface Accuracy in End Milling

1982 ◽  
Vol 104 (3) ◽  
pp. 272-278 ◽  
Author(s):  
W. A. Kline ◽  
R. E. DeVor ◽  
I. A. Shareef
Keyword(s):  
Optimization Problems ◽  
End Milling ◽  
Milling Process ◽  
Force System ◽  
Surface Error ◽  
Design And Optimization ◽  
Surface Errors ◽  
Cutter Deflection ◽  
The Difference ◽  
End Milling Process

In the end milling process, the cutting forces during machining produce deflection of the cutter and workpiece which result in dimensional inaccuracies or surface error on the finished component. A previously developed mathematical model for the cutting force system in end milling is combined with models for cutter deflection and workpiece deflection so that the surface error profile may be predicted from the machining conditions and geometry and material properties of the cutter and workpiece. Machining experiments are performed on rigid and flexible workpieces of 7075 aluminum to verify the ability of the models to predict surface error. The model predicted surface error profiles are accurate both in magnitude and shape with the difference between measured and predicted surface errors ranging from 5 to 15 percent. This approach for the prediction of surface errors provides a useful aid for the analysis of a variety of end milling process design and optimization problems.

Simulation of Surface Topography in Ball-End Milling Considering the Tool Deflection and Runout

2008 ◽  
Vol 375-376 ◽  
pp. 510-514 ◽  
Author(s):  
Jun Zhao ◽  
Xing Ai ◽  
Wen Yong Fang ◽  
Shi Guo Han
Keyword(s):  
End Milling ◽  
Milling Process ◽  
Tool Deflection ◽  
Machined Surface ◽  
Tool Runout ◽  
Ball End Milling ◽  
Proposed Model ◽  
Solid Ball ◽  
The Matrix ◽  
End Milling Process

The present work puts forward a generalized simulation model to evaluate the topography of ball-end milled surfaces by considering both the tool deflection and the tool runout. Firstly, a solid ball-end mill with S-shaped cutting edges is modeled as the basis. Then the tool tip trajectory is derived from the tool runout as well as the cutting forces induced tool deflection. And consequently the topography and scallop height of the machined surface are estimated by the numerical calculations of the matrix equations. With good expandibility, the proposed model can incorporate more machining information such as the movements of rotatory axes and tool wear, and hence, can be used to optimize the cutting conditions and parameters in 5-axis ball-end milling process.

TOPSIS based selection of optimal end milling process parameters

2020 ◽  
Author(s):  
A. Singh ◽  
I. Shivakoti ◽  
Z. Mustafa ◽  
R. Phipon ◽  
A. Sharma
Keyword(s):  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
End Milling Process ◽  
Selection Of

Machining feasibility and sustainability study on end milling process of Monel alloy

2021 ◽  
Author(s):  
Muhammed Shihan ◽  
J. Chandradass ◽  
T.T.M. Kannan ◽  
S.M. Sivagami
Keyword(s):  
End Milling ◽  
Milling Process ◽  
End Milling Process
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