Part Dimensional Error and Its Propagation Modeling in Multi-Operational Machining Processes

2003 ◽  
Vol 125 (2) ◽  
pp. 255-262 ◽  
Author(s):  
Qiang Huang ◽  
Jianjun Shi ◽  
Jingxia Yuan
Keyword(s):  
State Space Model ◽  
Machining Process ◽  
Kinematic Modeling ◽  
Machining Processes ◽  
Dimensional Error ◽  
Physical Relationship ◽  
Modeling And Control ◽  
Propagation Modeling ◽  
Variation Propagation ◽  
Machining Operations

In a multi-operational machining process (MMP), the final product variation is an accumulation or stack-up of variation from all machining operations. Modeling and control of the variation propagation is essential to improve product dimensional quality. This paper presents a state space model and its modeling strategies to describe the variation stack-up in MMPs. The physical relationship is explored between part variation and operational errors. By using the homogeneous transformation approach, kinematic modeling of setup and machining operations are developed. A case study with real machined parts is presented in the model validation.

scholarly journals Variation propagation modeling in multistage machining processes considering form errors and N-2-1 fixture layouts

2021 ◽  
Author(s):  
Filmon Yacob ◽  
Daniel Semere ◽  
Nabil Anwer
Keyword(s):  
Machining Process ◽  
Quality Prediction ◽  
Machining Processes ◽  
Variation Reduction ◽  
Propagation Modeling ◽  
Form Errors ◽  
Part Quality ◽  
Fixture Layout ◽  
Variation Propagation ◽  
Cad Cam

AbstractVariation propagation modeling of multistage machining processes enables variation reduction by making an accurate prediction on the quality of a part. Part quality prediction through variation propagation models, such as stream of variation and Jacobian-Torsor models, often focus on a 3-2-1 fixture layout and do not consider form errors. This paper derives a mathematical model based on dual quaternion for part quality prediction given parts with form errors and fixtures with N-2-1 (N>3) layout. The method uses techniques of Skin Model Shapes and dual quaternions for a virtual assembling of a part on a fixture, as well as conducting machining and measurement. To validate the method, a part with form errors produced in a two-stationed machining process with a 12-2-1 fixture layout was considered. The prediction made following the proposed method was within 0.4% of the prediction made using a CAD/CAM simulation when form errors were not considered. These results validate the method when form errors are neglected and partially validated when considered.

Modelling of Variation Propagation for Multi-Operational Machining Processes Based on Perturbation Vectors

2010 ◽  
Vol 36 ◽  
pp. 120-128 ◽  
Author(s):  
Z.J. Wen ◽  
Ping Yu Zhu ◽  
X.P. Zhang ◽  
H.C. Liu
Keyword(s):  
State Space ◽  
State Space Model ◽  
Machining Process ◽  
Machining Processes ◽  
Machining Error ◽  
Space Model ◽  
Proposed Model ◽  
Variation Propagation ◽  
Dimensional Variation

A new state space model of multi-operational machining processes is presented for dimensional variation propagation, transformation and accumulation based on perturbation vectors (PV). Taking perturbation vectors (PV) for state vectors of part geometric variaton and the fixture variations for input vectors, the perturbation homogeneous transformation (PHT) is applied to analyze and derivate datum-induced deviation, re-location deviation, fixture error and machining error, and a state space model of variation propagation in multi-operational complicated machining processes is developed. Furthermore, a three-operation machining process of cylinder is given to illustrate the method presented. With the results of calculation and simulation, it is verified that the proposed model is effective and useful.

Späne- und Stauberfassung bei der CFK-Zerspanung*/Extraction of chips and dust in machining operations of CFRP. Investigation on CFRP dry machining in industrial applications

2018 ◽  
Vol 108 (06) ◽  
pp. 473-478
Author(s):  
A. Gebhardt ◽  
M. Schneider
Keyword(s):  
Industrial Applications ◽  
Machining Process ◽  
Dry Machining ◽  
Machining Processes ◽  
Dry Cutting ◽  
Clamping System ◽  
Cutting Processes ◽  
Machining Operations

Bauteile aus CFK (kohlenstofffaserverstärkte Kunststoffe) werden meist spanend endbearbeitet. Diese Bearbeitung kann unter Überflutung durch KSS (Kühlschmierstoffe) oder trocken stattfinden. Die hier vorgestellte Studie zeigt für die Trockenzerspanung, wie die notwendige Erfassung von Stäuben und Spänen stattfindet, welche Technologien eingesetzt werden und wie eine Maschinen- und Bauteilreinigung aussieht.   A machining process is mostly used as a last step in the production of workpieces made of CFRP. In this machining process lubricants may be used or dry cutting processes are applicated. The here presented study shows for dry machining processes, which technologies are used for the dust and chip extraction. Furthermore, the techniques for the cleaning of the machine, the clamping system and workpiece are presented.

Multi-Operational Machining Processes Modeling for Sequential Root Cause Identification and Measurement Reduction

2004 ◽  
Author(s):  
Hui Wang ◽  
Qiang Huang ◽  
Reuven Katz
Keyword(s):  
Machine Tool ◽  
Propagation Model ◽  
Machining Processes ◽  
Error Sources ◽  
Variation Reduction ◽  
Measurement Reduction ◽  
Propagation Modeling ◽  
Root Cause ◽  
Variation Propagation ◽  
Root Cause Identification

Variation propagation modeling has been proved to be an effective way for variation reduction and design synthesis in multi-operational manufacturing processes (MMP). However, previously developed approaches for machining processes did not directly model the process physics regarding how fixture, and datum, and machine tool errors generate the same pattern on part features. Consequently, it is difficult to distinguish error sources at each operation. This paper formulates the variation propagation model using the proposed equivalent fixture error (EFE) concept. With this concept, datum error and machine tool error are transformed to equivalent fixture locator errors at each operation. As a result, error sources can be grouped and root cause identification can be conducted in a sequential manner. The case studies demonstrate the model validity through a real cutting experiment and model advantage in measurement reduction for root cause identification.

A Quality Prediction Framework for Multistage Machining Processes Driven by an Engineering Model and Variation Propagation Model

2007 ◽  
Vol 129 (6) ◽  
pp. 1088-1100 ◽  
Author(s):  
Jianming Li ◽  
Theodor Freiheit ◽  
S. Jack Hu ◽  
Yoram Koren
Keyword(s):  
Dimensional Accuracy ◽  
Software Tool ◽  
Propagation Model ◽  
System Level ◽  
Quality Prediction ◽  
Machining Processes ◽  
Propagation Modeling ◽  
Variation Propagation ◽  
Quality Modeling ◽  
Dimensional Variation

This paper proposes a comprehensive quality prediction framework for multistage machining processes, connecting engineering design with the activities of quality modeling, variation propagation modeling and calculation, dimensional variation evaluation, dimensional variation analysis, and quality feedback. Presented is an integrated information model utilizing a hybrid (feature/point-based) dimensional accuracy and variation quality modeling approach that incorporates Monte Carlo simulation, variation propagation, and regression modeling algorithms. Two important variations (kinematic and static) for the workpiece, machine tool, fixture, and machining processes are considered. The objective of the framework is to support the development of a quality prediction and analysis software tool that is efficient in predicting part dimensional quality in a multistage machining system (serial, parallel, or hybrid) from station level to system level.

Results of an Experimental Research Concerning the Evaluation of Machinability by Drilling under Constant Feed Force

2015 ◽  
Vol 809-810 ◽  
pp. 147-152 ◽  
Author(s):  
Vasile Manole ◽  
Laurenţiu Slătineanu ◽  
Sergiu Constantin Olaru ◽  
Irina Beşliu ◽  
Pavel Iurea ◽  
...  
Keyword(s):  
Machining Process ◽  
Normal Operation ◽  
Time Interval ◽  
Experimental Setup ◽  
Machining Processes ◽  
Drilling Tool ◽  
Feed Force ◽  
Machining Operations ◽  
Tool Diameter ◽  
The Impact

The knowledge about machinability indices for distinct machining processes allows finding the most appropriate values of the relevant factors for definite machining operations. Several criteria can be used to characterize machinability, such as the tool wear, the magnitude of the cutting forces, the roughness of the machined surfaces, or the shape of the chips that are formed during the machining process. One of the methods for studying the machinability is based on the analysis of drilling operations that are made under constant feed force. A drill press is probably the most readily available device to implement an experimental setup for drilling machinability tests. In normal operation, however, the chip accumulation at the dead end of the machined hole has a detrimental impact on the results of machinability tests, so that an improved setup was designed. A two-level, full factorial experiment with three independent factors (the drilling tool diameter, the rotational speed of the spindle and the feed force) has proven the suitability of the new experimental setup. Using it, we could find a power-type empirical model that explains the impact of the input factors in the depth of a hole that is machined in a pre-defined time interval.

Numerical-Experimental Correlation of Distortions Induced by Machining Process on Thin-Walled Nickel Super Alloy Forged Components

2012 ◽  
Vol 504-506 ◽  
pp. 1299-1304 ◽  
Author(s):  
Antonio del Prete ◽  
Antonio Alberto de Vitis ◽  
Rodolfo Franchi
Keyword(s):  
Numerical Models ◽  
Model Development ◽  
Aircraft Engine ◽  
Machining Process ◽  
Work Piece ◽  
Machining Processes ◽  
Thin Walled ◽  
Main Components ◽  
Machining Operations

AeroEngines main components made by nickel super alloys are mainly obtained by machining of large forged components. The work piece machining process generates some distortions that may also be relevant. In this contest, in many cases the removed volume in the machining operations represents a large percentage of the forged component in order to obtain the thin-walled wanted geometry. Due to this reason, the residual bulk stresses induced by the process history can lead to significant 3D geometric distortions in the machined component with unacceptable dimensions and shapes of the obtained product for comparison with the wanted geometry. Moreover, it is a matter of fact how, the final component distortions depend by the cutting strategy adopted in the machining process. The experimental study of such cutting strategies on real components are particularly time consuming and costly and for this reason the chance to study the problem using reliable numerical models it is particularly welcome. In the present work authors reports the numerical model development of the forging and machining processes needed for the production of a aircraft engine component and the comparison of the obtained results with the ones physically measured. The objective is to develop and validate a modeling method able to predicts the shape and the magnitude of the distortion induced by the machining operation on the considered component and to establish a possible strategy to suggest machining working steps able to improve the quality of the manufactured component reducing the needed production time.

Quality Assured Setup Planning Based on the Stream-of-Variation Model for Multi-Stage Machining Processes

2006 ◽  
Author(s):  
Jian Liu ◽  
Jianjun Shi ◽  
S. Jack Hu
Keyword(s):  
Product Quality ◽  
Cost Effective ◽  
Machining Process ◽  
Manufacturing Processes ◽  
Setup Planning ◽  
Machining Processes ◽  
Multi Stage ◽  
Variation Propagation ◽  
Stream Of Variation ◽  
The Cost

Setup planning is a set of activities to arrange manufacturing features into an appropriate sequence for processing. As such, setup planning can significantly impact the product quality in terms of dimensional variation in the Key Product Characteristics (KPC’s). Current approaches in setup planning are experience-based and tend to be conservative by selecting unnecessarily precise machines and fixtures to ensure final product quality. This is especially true in multi-stage manufacturing processes because it has been difficult to predict the variation propagation and its impact on KPC quality. In this paper, a new methodology is proposed to realize cost-effective, quality ensured setup planning for multi-stage manufacturing processes. Setup planning is formulated as an optimization problem based on quantitative evaluation with the Stream-of-Variation (SoV) models. The optimal setup plan minimizes the cost related to process precision and satisfies the quality specifications. The effectiveness of the proposed approach is demonstrated through setup planning for a multi-stage machining process.

scholarly journals Characteristics and Wear Mechanisms of TiAlN-Based Coatings for Machining Applications: A Comprehensive Review

Metals ◽  
2021 ◽  
Vol 11 (2) ◽  
pp. 260
Author(s):  
Vitor F. C. Sousa ◽  
Francisco José Gomes Da Silva ◽  
Gustavo Filipe Pinto ◽  
Andresa Baptista ◽  
Ricardo Alexandre
Keyword(s):  
Mechanical Properties ◽  
Wear Behavior ◽  
Machining Process ◽  
Machining Processes ◽  
Process Improvements ◽  
Tool Coatings ◽  
Recent Developments ◽  
Machining Operations ◽  
Industry Sectors ◽  
Cutting Behavior

The machining process is still a very relevant process in today’s industry, being used to produce high quality parts for multiple industry sectors. The machining processes are heavily researched, with the focus on the improvement of these processes. One of these process improvements was the creation and implementation of tool coatings in various machining operations. These coatings improved overall process productivity and tool-life, with new coatings being developed for various machining applications. TiAlN coatings are still very present in today’s industry, being used due to its incredible wear behavior at high machining speeds, high mechanical properties, having a high-thermal stability and high corrosion resistance even at high machining temperatures. Novel TiAlN-based coatings doped with Ru, Mo and Ta are currently under investigation, as they show tremendous potential in terms of mechanical properties and wear behavior improvement. With the improvement of deposition technology, recent research seems to focus primarily on the study of nanolayered and nanocomposite TiAlN-based coatings, as the thinner layers improve drastically these coating’s beneficial properties for machining applications. In this review, the recent developments of TiAlN-based coatings are going to be presented, analyzed and their mechanical properties and cutting behavior for the turning and milling processes are compared.

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