Error Source Diagnostics Using a Turning Process Simulator

1998 ◽  
Vol 120 (2) ◽  
pp. 409-416 ◽  
Author(s):  
Sung-Gwang Chen ◽  
A. Galip Ulsoy ◽  
Yoram Koren
Keyword(s):  
Process Simulation ◽  
Cutting Process ◽  
Force Model ◽  
Error Source ◽  
Turning Process ◽  
Cutting Force Model ◽  
Cnc Lathe ◽  
Computer Numerically Controlled ◽  
Simulation Results ◽  
Process Simulator

To improve productivity and quality in machining, it is necessary to understand the interactions among machine tool components and the cutting process. This paper presents a model that characterizes interactions among the subsystems of a computer numerically controlled (CNC) lathe. The model is combined with a cutting force model to obtain a comprehensive turning simulator that simulates the cutting forces and part dimensions. A series of calibration experiments are proposed and implemented for process simulation. The simulation results are good when compared with experimental measurements. The interactions among the subunits of a CNC lathe and the cutting process are found to be potentially important.

Accurate Milling Process Simulation Using ME Z-Map Model

Manufacturing ◽  
2003 ◽  
Author(s):  
Han Ul Lee ◽  
Dong-Woo Cho
Keyword(s):  
Cutting Force ◽  
Process Simulation ◽  
Cutting Forces ◽  
Computing Time ◽  
Milling Process ◽  
Simulation System ◽  
Grid Size ◽  
Force Model ◽  
Cutting Force Model ◽  
Edge Node

In this paper, a milling process simulation system was constructed and ME Z-map (Moving Edge node Z-map) model was developed to elevate the performance of this system. The milling process simulation system computes the cutting configuration and then the cutting forces are predicted using these calculated configurations. In this system, an improved cutting force model which is independent of cutting conditions is used to more precisely predict the cutting forces. In the process, the ME Z-map model was used for more accurate computing of cutting configuration. Due to the edge node, ME Z-map model produces more accurate cutting configuration than the conventional Z-map models even with five to ten times larger grid size, which reduces the computing time dramatically. The superiority of the ME Z-map model was confirmed through comparison with the conventional Z-map.

Dynamic Behavior of a Thin-Walled Cylindrical Workpiece During the Turning Process, Part 1: Cutting Process Simulation

2002 ◽  
Vol 124 (3) ◽  
pp. 562-568 ◽  
Author(s):  
K. Mehdi ◽  
J.-F. Rigal ◽  
D. Play
Keyword(s):  
Dynamic Behavior ◽  
Process Simulation ◽  
Point Of View ◽  
Cutting Process ◽  
Natural Phenomenon ◽  
Chatter Vibration ◽  
Turning Process ◽  
Chatter Vibrations ◽  
Cylindrical Workpiece ◽  
Thin Walled

From a practical point of view, in machining applications, chatter vibration constitutes a major problem during the cutting process. It is becoming increasingly difficult to suppress chatter during cutting at high speeds. Many investigators have regarded chatter vibrations as a “natural” phenomenon during the cutting process and a part of the process itself. In classical machining operations with thick-walled workpieces chatter vibrations occur when the cutting depth exceeds stability limits dependent on the machine tool. On the other hand, in the case of thin-walled cylindrical workpieces, chatter vibration problems are not so simple to formulate. The main purpose of this study is to qualify the dynamic behavior of a thin-walled workpiece during the turning process. It contains two parts: the cutting process simulation and the definition of experimental stability criteria. In the first part, a numerical model, which simulates the turning process of thin-walled cylindrical workpieces, is proposed. This model also permits obtaining workpiece responses to excitation generated by cutting forces. Finally, the stability of the process is discussed.

scholarly journals Preparation and Characterization of Ultra-Thin Dicing Blades With Different Bonding Properties

2021 ◽  
Author(s):  
Zewei Yuan ◽  
Shuang Feng ◽  
Tianzheng Wu
Keyword(s):  
Cutting Force ◽  
Cutting Process ◽  
Force Model ◽  
Cutting Force Model ◽  
Abrasive Particles ◽  
Experimental Apparatus ◽  
The Matrix ◽  
Bonding Properties ◽  
Set Up ◽  
Deviation Coefficient

Abstract Ultra-thin dicing blade is usually used to achieve a high precision cutting in semiconductor back-end packaging and assembly. Lots of interactional parameters involving in dicing blade preparation and cutting process bring difficulties to high cutting qualities and good working life of dicing blade. In order to address these problems, this study prepared three kinds of dicing blades and characterized the cutting properties of three dicing blades. It first proposed the abrasive exposure coefficient and tool deviation coefficient to provide parameters for the cutting force model. Then the experimental apparatus was set up to verify the proposed cutting force model. And a series of parameters including feed rate, spindle current, edge chipping coefficient, tool wear amount and grinding performance are used to characterize the comprehensive performance of prepared dicing blades. Finally, the edge morphology was observed under 3D microscope to analysis the hardness of different dicing blades. The theoretical and experimental results indicate that the proposed cutting force model can reflect actual cutting process. There is an inverse proportional function between the shedding of abrasive particles and the hardness of the matrix. The cutting performance of dicing blades is very dependent on the material of workpiece. C-dicing blades presents outstanding comprehensive effects with small chips and good self-sharpening properties.

Chatter in Turning Process Incorporating the Effect of Ploughing Force

1999 ◽  
Author(s):  
Z. C. Wang ◽  
W. L. Cleghorn ◽  
S. D. Yu
Keyword(s):  
Stability Analysis ◽  
Cutting Force ◽  
Force Model ◽  
Turning Process ◽  
Cutting Force Model ◽  
Stability Curve ◽  
Characteristic Roots ◽  
The Laplace Transform ◽  
Machining System ◽  
The Stability

Abstract In this paper, the stability analysis of turning process is performed based on a new cutting force model which includes the effect of ploughing force. This approach utilized the Laplace transform to identify the characteristic roots of the examined machining system. The stability of the machining system can then be determined by examining the locations of the characteristic roots. The stability curve for a specific turning process can then be plotted. The effect of different cutting force models on the stability is also investigated. The results clearly demonstrate some chatter phenomena observed by other researchers.

A 3-D Closed-Form Cutting Force Model for End Milling With Application to Sculptured Surface Milling

1999 ◽  
Author(s):  
T. S. Lee ◽  
R. Farahati ◽  
Y. J. Lin
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Free Form ◽  
Depth Of Cut ◽  
Force Model ◽  
Sculptured Surface ◽  
Cutting Force Model ◽  
Estimation Scheme ◽  
Simulation Results ◽  
Axial Depth

Abstract A comprehensive, 3D mathematical model of desired/optimal cutting force for end milling of free-form surfaces is proposed in this paper. The closed-form predictive model is developed based on a perceptive cutting approach resulting in a cutting force model having a comprehensive set of essential cutting parameters. In particular, the normal rake angle usually missing in most existing models of the same sort is included in the developed model. The model also enables quantitative analyses of the effect of any parameters on the cutting performance of the tool, providing a guideline to improving the tool performance. Since the axial depth of cut varies with time when milling sculptured surface parts, an innovative axial depth of cut estimation scheme is proposed for the generation of 3-D cutting forces. This estimation scheme improves the practicality of most existing predictive cutting force model for milling in which the major attention has been focused on planar milling surface generation. In addition, the proposed model takes the rake surface on the flute of mills as an osculating plane to yield 3-D cutting force expressions with only two steps. This approach greatly reduces the time-consuming mathematical work normally required for obtaining the cutting force expressions. A series of milling simulations for machining free-form parts under scenario cutting conditions have been performed to verify the effectiveness of the proposed cutting force model. The simulation results demonstrate accurate estimating capability of the proposed method for the axial depth of cut estimation. The cutting force responses from the simulation exhibit the same trends as what can be obtained using the empirical mechanic’s model referenced in the literature. Finally, through the simulation results it is also learned that designing a tool with a combination of different helix angles having cutting force signatures similar to that of the single helix angle counterparts is particularly advantageous.

Stability of turning process with a distributed cutting force model

2018 ◽  
Vol 102 (5-8) ◽  
pp. 1215-1225
Author(s):  
Yonglin Wu ◽  
Qinghua Song ◽  
Zhanqiang Liu ◽  
Bing Wang
Keyword(s):  
Cutting Force ◽  
Force Model ◽  
Turning Process ◽  
Cutting Force Model

Dynamic Analysis of Slender Shaft in Twin-Spindle Turning

2011 ◽  
Vol 48-49 ◽  
pp. 448-454 ◽  
Author(s):  
Kai Bo Lu ◽  
Min Qing Jing ◽  
Heng Liu ◽  
Chun Xiao Cong
Keyword(s):  
Cutting Forces ◽  
Natural Frequencies ◽  
Technical Difficulty ◽  
Force Model ◽  
Analysis Method ◽  
Turning Process ◽  
Cutting Force Model ◽  
Rotating Shaft ◽  
Dynamic Cutting Force ◽  
Stiffening Effect

Machining slender workpiece is still a technical difficulty. This paper investigates the dynamic behavior of a slender shaft subject to constant feedrate moving cutting forces in twin-spindle turning process. The Euler-Bernoulli theory is used to model the rotating shaft. A dynamic cutting force model is formulated considering the flexibility of workpiece and rigid machine tool. The modal analysis method is employed to solve the dynamic response of the shaft. The parametric influence to the response and natural frequencies of shaft is discussed. Finally, the results are presented and compared between constant cutting forces and deflection-dependent force model introduced in this paper. It is found that there exists a stiffening effect due to the cutting process.

A Method to Select Optimal Cutting Force Model Using the Measured Process Transfer Function

2014 ◽  
Vol 597 ◽  
pp. 195-202
Author(s):  
Ming Zhu ◽  
Xun Xing Yu ◽  
Wei Wei Xiao ◽  
Kuan Min Mao
Keyword(s):  
Transfer Function ◽  
Cutting Force ◽  
Experimental Method ◽  
Cutting Process ◽  
Force Model ◽  
Complex Frequency ◽  
Cutting Force Model ◽  
Cutting Stability ◽  
Process Transfer ◽  
Measured Process

The cutting stability is determined by the dynamics of the tool-workpiece and the cutting process. Several cutting force models have been established by the former researches. Based on the analysis of the cutting process transfer function derived from the cutting force models, the characteristics of these models were analyzed in this work by ploting the function curves in the complex frequency plane. The curve shapes and centers were considered as the indicator to estimate the suitability of a cutting force model. An experimental method was proposed to select suitable cutting force model for a real cutting process.

Modeling of the Thread Milling Operation in a Combined Thread/Drilling Operation: Thrilling

2010 ◽  
Vol 132 (1) ◽  
Author(s):  
Martin B. G. Jun ◽  
Anna Carla Araujo
Keyword(s):  
Cutting Force ◽  
Model Comparison ◽  
Complex Geometry ◽  
Chip Thickness ◽  
Force Model ◽  
Cutting Force Model ◽  
Tool Paths ◽  
Milling Operation ◽  
Thread Milling ◽  
Simulation Results

This paper investigates a thread making process called thrilling, which performs both drilling and thread milling with one tool. A chip thickness and mechanistic cutting force model has been developed for a thread milling operation with a thrilling tool. The model considers the complex geometry of a thrilling tool and the unique tool paths associated with the thread milling operation. Experiments have been conducted to validate the developed model. Comparison of the average torque and forces between experiment and simulation results shows that the model predicts the experimental results within 12% error.

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