The Effects of Variable Speed Cutting on Vibration Control in Face Milling

1990 ◽  
Vol 112 (1) ◽  
pp. 1-11 ◽  
Author(s):  
S. C. Lin ◽  
R. E. DeVor ◽  
S. G. Kapoor
Keyword(s):  
Vibration Control ◽  
Vibration Suppression ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Force Model ◽  
Trajectory Design ◽  
Variable Speed ◽  
Milling Force Model

This paper discusses the use of variable speed cutting for vibration control in the face milling process. Both simulation and experimental results show that the self-excited vibrations that can occur during constant speed cutting, and hence put limitation on the possible size of cut, can be suppressed by continuously varying the spindle speed. Through both analytical and experimental studies, the shape of variable speed trajectory has been examined, in terms of both the trackability by the spindle servo system and performance in terms of vibration suppression. It was found that a sinusoidal wave because of its acceleration and jerk characteristics can be tracked more precisely than some other periodic waves. The dynamic face milling force model was used to study the effects of speed trajectory parameters, namely, the frequency and amplitude. The results, in general, show the method to be fairly robust to the specific nature of the machining situation in terms of both processing conditions and system dynamics. Speed trajectory design was, however, shown to be somewhat dependent upon the nominal cutting speed and dominant frequencies of the system.

Multi-Toothed Milling Force Model and Simulation for Form Milling the Gear of the Hypoid Gears

2011 ◽  
Vol 328-330 ◽  
pp. 90-95 ◽  
Author(s):  
Xin Jie Jia ◽  
Xiao Zhong Deng ◽  
Xiao Zhong Ren
Keyword(s):  
Face Milling ◽  
Force Model ◽  
Geometrical Theory ◽  
Hypoid Gear ◽  
Milling Force ◽  
Hypoid Gears ◽  
Model And Simulation ◽  
Simulation Results ◽  
Milling Forces ◽  
Milling Force Model

Prediction of the forces in milling hypoid gear was often needed in order to establish automation and optimization of the tooth-milling processes. Based on the geometrical theory of the format face-milling, the multi-toothed milling forces theoretical model for form milling the gear of the hypoid gears is presented, the milling force factors were calibrated via single factor experiments and the simulation programs were prepared. Experiments were carried out to verify the availability of the multi-toothed dynamic milling force model, the experimental results is consistent with the simulation results.

Chatter Stability Analysis of the Variable Speed Face-Milling Process

2000 ◽  
Vol 123 (4) ◽  
pp. 753-756 ◽  
Author(s):  
Sridhar Sastry, ◽  
Shiv G. Kapoor, ◽  
Richard E. DeVor, and ◽  
Geir E. Dullerud
Keyword(s):  
Discrete System ◽  
Milling Process ◽  
Face Milling ◽  
Solution Technique ◽  
Dimensional System ◽  
Multiple Time ◽  
Time Varying ◽  
Variable Speed ◽  
Finite Dimensional ◽  
Industrial Grade

In this study, a solution technique based on a discrete time approach is presented to the stability problem for the variable spindle speed face-milling process. The process dynamics are described by a set of differential-difference equations with time varying periodic coefficients and time delay. A finite difference scheme is used to discretize the system and model it as a linear time varying (LTV) system with multiple time delays. By considering all the states over one period of speed variation, the infinite dimensional periodic time-varying discrete system is converted to a finite dimensional time-varying discrete system. The eigenvalues of the state transition matrix of this finite dimensional system are then used to propose criteria for exponential stability. Predicted stability boundaries are compared with lobes generated by numerical time-domain simulations and experiments performed on an industrial grade variable speed face-milling testbed.

scholarly journals Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

2021 ◽  
pp. 71-84
Author(s):  
Nhu-Tung Nguyen ◽  
Dung Hoang Tien ◽  
Nguyen Tien Tung ◽  
Nguyen Duc Luan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
High Speed Milling

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

scholarly journals A method of predicting the best conditions for large-size workpiece clamping to reduce vibration in the face milling process

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Krzysztof J. Kaliński ◽  
Natalia Stawicka-Morawska ◽  
Marek A. Galewski ◽  
Michał R. Mazur
Keyword(s):  
Natural Frequencies ◽  
Vibration Suppression ◽  
Milling Process ◽  
Face Milling ◽  
Modal Identification ◽  
Large Size ◽  
Innovative Method ◽  
The Face ◽  
The Time Domain ◽  
Minimum Work

AbstractThe paper presents an innovative method of solving the problem of vibration suppression during milling of large-size details. It consists in searching for the best conditions for clamping the workpiece based on a rapid modal identification of the dominant natural frequencies only and requires repetitive changes in the tightening torque of the clamping screws. Then, by estimating the minimum work of the cutting forces acting in the direction of the width of the cutting layer, it is possible to predict the best fixing of the workpiece. Application of the method does not require the creation and identification of a computational model of the process or preliminary numerical simulations. The effectiveness of this method was confirmed by the evaluation of the Root Mean Square (RMS) of the vibration level in the time domain observed during the actual face milling process. The worst results were obtained for the configuration of supports tightened with a torque of 90–110 Nm, and the best—with a torque of 50 Nm.

scholarly journals Multi-Response Optimization of Face Milling Performance Considering Tool Path Strategies in Machining of Al-2024

Materials ◽  
2019 ◽  
Vol 12 (7) ◽  
pp. 1013 ◽  
Author(s):  
Raneen Ali ◽  
Mozammel Mia ◽  
Aqib Khan ◽  
Wenliang Chen ◽  
Munish Gupta ◽  
...  
Keyword(s):  
Tool Path ◽  
Removal Rate ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
Cutter Path ◽  
Response Optimization ◽  
Grey Relational ◽  
Al 2024

It is hypothesized that the orientation of tool maneuvering in the milling process defines the quality of machining. In that respect, here, the influence of different path strategies of the tool in face milling is investigated, and subsequently, the best strategy is identified following systematic optimization. The surface roughness, material removal rate and cutting time are considered as key responses, whereas the cutting speed, feed rate and depth of cut were considered as inputs (quantitative factors) beside the tool path strategy (qualitative factor) for the material Al 2024 with a torus end mill. The experimental plan, i.e., 27 runs were determined by using the Taguchi design approach. In addition, the analysis of variance is conducted to statistically identify the effects of parameters. The optimal values of process parameters have been evaluated based on Taguchi-grey relational analysis, and the reliability of this analysis has been verified with the confirmation test. It was found that the tool path strategy has a significant influence on the end outcomes of face milling. As such, the surface topography respective to different cutter path strategies and the optimal cutting strategy is discussed in detail.

The Study of Surface Finish in Face Milling of Stainless Steel: AISI 304

2013 ◽  
Vol 650 ◽  
pp. 606-611 ◽  
Author(s):  
Songsak Luejanda ◽  
Komson Jirapattarasilp
Keyword(s):  
Stainless Steel ◽  
Surface Finish ◽  
Feed Rate ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
Aisi 304 ◽  
Steel Aisi ◽  
Stainless Steel Aisi

This research was to study the effect of face milling on the surface finish of stainless steel: AISI 304. The experiment was applied on three factors and were consisted of three levels of cutting speed, depth of cut and feed rate. The face milling process was chosen to experiment which used face milling cutter with insert carbide tool. The surface roughness average (Ra) was applied to indicating for surface finish. The experiment results were analyzed by ANOVA. The main factors and factors interaction that affected to surface finish were investigated. Effect of cutting speed, feed rate and depth of cut on surface finish of stainless steel: AISI 304 was discussed.

Optimization of Axial Rake Angle for Face Milling Using Taguchi Method and Finite Element Analysis

2013 ◽  
Vol 465-466 ◽  
pp. 746-750 ◽  
Author(s):  
Mohd Riduan Ibrahim ◽  
A.R. Abd. Kadir ◽  
M.S. Omar ◽  
M.H. Osman ◽  
S. Sulaiman ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Optimal Parameter ◽  
Signal To Noise Ratio ◽  
Cutting Speed ◽  
Rake Angle ◽  
Milling Process ◽  
Face Milling ◽  
Element Analysis ◽  
Confirmation Test

This study employed the Taguchi approach in combination with finite element analysis (DEFORM3D) to investigate face milling process onto AL6061. The factors studied in this investigation were cutting speed, feed rate, and axial rake angle. The simulation of flank wear was generated according to Usuis wear model though the L9(34) of the orthogonal array experiment. ANOVA analysis and F test were conducted to find the significant factor that contributes to tool wear in the signal to noise ratio. Finally, the confirmation test has been carried out at optimal parameter.

Research on Error Compensation of Corner Milling Process Based on Milling Force Prediction

2014 ◽  
Vol 800-801 ◽  
pp. 761-765
Author(s):  
Hui Nan Shi ◽  
Fu Gang Yan ◽  
Yun Peng Ding ◽  
Xian Li Liu ◽  
Rui Zhang
Keyword(s):  
Error Compensation ◽  
Chip Thickness ◽  
Milling Process ◽  
Force Model ◽  
Deformation Model ◽  
Milling Force ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Flexible Deformation ◽  
Milling Force Model

In cavity die corner-machining, tool flexible deformation caused by the milling force resulting in the surface error, a method of off-line error compensation is put forward. Instantaneous chip thickness model and the corner milling force model is established based on differential and the characteristics of the corner. Combining the theory of cantilever beam and the finite element analysis, cutting tool elastic deformation model is established.

Analysis to Milling Force Base on AdvantEdge Finite Element Analysis

2014 ◽  
Vol 981 ◽  
pp. 895-898
Author(s):  
Fu Cai Zhang ◽  
Qing Wang ◽  
Ru Yang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Simulation Analysis ◽  
Cutting Parameters ◽  
Milling Process ◽  
Force Model ◽  
Cnc Milling ◽  
Milling Force ◽  
Element Analysis ◽  
Milling Force Model

Aiming at NC milling processing simulation problem, a ball-end cutter milling force model is established, the numerical simulation analysis of aluminum alloy AL2024 milling process is conducted by using the finite element analysis software AdvantEdge finite element analysis. Focus on the Milling force simulation, the size of the milling force is obtained by simulating calculation. Using the same cutting parameters for milling experiment, the results show that simulation analysis of the cutting force values ​​are in good agreement with the experimental results，the milling force model prior established is correct. The research laid a foundation for the perfect CNC milling simulation system.

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