Optimal Rough Machining of Sculptured Parts on a CNC Milling Machine

1993 ◽  
Vol 115 (4) ◽  
pp. 424-431 ◽  
Author(s):  
Z. Dong ◽  
H. Li ◽  
G. W. Vickers
Keyword(s):  
Production Costs ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Rough Machining ◽  
Machining Time ◽  
Tool Paths ◽  
Cnc Milling Machine ◽  
Cnc Programming ◽  
Sculptured Parts ◽  
Optimal Approach

An optimal approach to the rough machining of sculptured parts with least machining time is presented. The contour map cutting method is used to generate CNC tool paths based on the CAD model of sculptured parts. The part and stock geometry related parameters, including the number of cutting layers and the distributions of cutting depth, and the process parameters of feed rate and depth of cut, are optimized. The method can automate CNC programming for sculptured part rough machining, considerably improve productivity, and lower production costs. Two examples are used to illustrate the approach and its advantages.

Improving Rough Cutting Efficiency for Machining of Impellers

2004 ◽  
Author(s):  
Der-Min Tsay ◽  
Chien-Wen Chen
Keyword(s):  
End Milling ◽  
Geometric Model ◽  
Production Costs ◽  
Cnc Milling ◽  
Rough Machining ◽  
Tool Paths ◽  
Cnc Milling Machine ◽  
Computer Numerically Controlled ◽  
Step Interval ◽  
Time Required

A procedure that can be used to generate rough cutting tool paths with minimized variations of material removal rates (MRRs) is developed for 5-axis ball end milling of centrifugal compressor impellers. Based on the geometric model of impellers, the detailed processes in finding the cutter contact (CC) points with equal spacing for step interval between two adjacent tool paths and a constant depth between two neighboring cutting layers are presented. The developed system can considerably improve productivity and lower production costs in rough machining since the time required can be reduced by minimizing the waste tool paths. Simulation and machining tests by a 5-axis computer numerically controlled (CNC) milling machine are performed to illustrate the procedure and its advantages.

Study on Intelligent Control of Milling Process Based on MATLAB

2011 ◽  
Vol 328-330 ◽  
pp. 1759-1762
Author(s):  
Xing Yu Lai ◽  
Chun Yan Yan ◽  
Bang Yan Ye ◽  
Wei Guang Li
Keyword(s):  
Intelligent Control ◽  
Milling Process ◽  
Depth Of Cut ◽  
Cnc Machine Tool ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Experimental Platform ◽  
Simulink Model ◽  
Cnc Milling Machine ◽  
Constant Cutting Force

In order to achieve the intelligent control of milling process, an experimental platform is constructed in XK5140 CNC machine tool. The control system is based on the Simulink model of MATLAB and the controller is established by programming S-function. The experiments are performed on steel workpiece with variable depth of cut by controlling milling force. The experimental results show that the intelligent control of the milling process is feasible using this experimental platform. The proposed controller can adaptively adjust the feed rate till achieving a constant cutting force approaching the set point in varied cutting conditions. CNC milling machine can make full use of its manufacturing capacity when processing the parts, thus improving the cutting efficiency and protecting the tool.

The Study of Tool Wear Performance on Pocket Milling Strategy

2014 ◽  
Vol 699 ◽  
pp. 64-69 ◽  
Author(s):  
A.B. Mohd Hadzley ◽  
A. Siti Sarah ◽  
R. Izamshah ◽  
M.R. Nurul Fatin
Keyword(s):  
Tool Wear ◽  
Tool Path ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cnc Milling ◽  
Wear Performance ◽  
Pocket Milling ◽  
Cnc Milling Machine ◽  
Radial Depth ◽  
Wet Condition

The increasing productivity demand in machining industry has lead for fast material removal machining technique of pocket milling using different tool path strategies. This project aims to study about the effect of different tool path strategies on tool wear when machining aluminium alloy 7076. Five milling strategies were evaluated outward helical, inward helical, back and forth, offset on part one-way and offset on part zigzag. CATIA V5R19 was used to setup milling path and the machining experiments were carried out on a HAAS’ 3 axis CNC milling machine. The machining was held under wet condition with 2500 rpm cutting speed, 800 mm/min feed rate, 2 mm radial depth of cut and 2 mm axial depth of cut. The results showed that the best tool path strategies are inward helical and offset on part one-way, while the worst tool path strategy is outward helical. Failure to evacuate chip during pocket milling is the main reason to cause rapid tool wear due to temperature rise and higher contact time and area of cutting tool with the chip. Results from this experiment help to guide the machinist to perform pocket milling effectively.

scholarly journals OPTIMASI PARAMETER PERMESINAN TERHADAP WAKTU PROSES PADA PEMROGRAMAN CNC MILLING DENGAN BERBASIS CAD/CAM

2016 ◽  
Vol 6 (1) ◽  
Author(s):  
I G.N.K. Yudhyadi ◽  
Tri Rachmanto ◽  
Adnan Dedy Ramadan
Keyword(s):  
Cutting Speed ◽  
Operation Time ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine ◽  
Machining Parameter

Milling process is one of many machining processes for manufacturing component. The length of time in the process of milling machining is influenced by selection and design of machining parameters including cutting speed, feedrate and depth of cut. The purpose of this study to know the influence of cutting speed, feedrate and depth of cut as independent variables versus operation time at CNC milling process as dependent variables. Each independent variable consists of three level of factors; low, medium and high.Time machining process is measured from operation time simulation program, feed cut length and rapid traverse length. The results of statistically from software simulation MasterCam X Milling, then do comparison to CNC Milling machine.  The data from experiments was statistical analyzed by Anova and Regression methods by software minitab 16.Results show that the greater feedrate and depth of cut shorten the operation time of machinery, whereas cutting speed is not significant influence. Depth of cut has the most highly contribution with the value of 49.56%, followed by feedrate 43% and cutting speed 0.92%. Optimal time of machining process total is 71.92 minutes, with machining parameter on the condition cutting speed is 75360 mm/minutes, feedrate is 800 mm/minutes and depth of cut = 1 mm. Results of comparison time machining process in software Mastercam X milling with CNC Milling machine indicates there is difference not significant with the value of 0,35%.

scholarly journals Sustainable Manufacturing and Parametric Analysis of Mild Steel Grade 60 by Deploying CNC Milling Machine and Taguchi Method

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1303
Author(s):  
Shakir Azim ◽  
Sahar Noor ◽  
Qazi Salman Khalid ◽  
Aqib Mashood Khan ◽  
Danil Yurievich Pimenov ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Feed Rate ◽  
Sustainable Manufacturing ◽  
Steel Grade ◽  
Spindle Speed ◽  
Depth Of Cut ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine

Design and manufacturing are the key steps in the sustainable manufacturing of any product to be produced. Within the perspective of injection molds production, increased competitiveness and repeated changes in the design require a complete optimized manufacturing process. Local and minor improvements in the milling process do not generally lead to an optimized manufacturing process. The goal of the new geometry and parametric analysis of the mould is to reduce the quality issues in mild steel grade 60. In this explicit research, the surface roughness (smoothness) of indigenously produced injection moulds in the local market in Pakistan is investigated. The CNC milling machine (five-axis) is used for the manufacturing of an injection mould, and the Taguchi method of the design of the experiment is applied for parameters optimization. Hence, the overall process is assisted in balancing the milling machine parameters to trim down the surface roughness issue in mild steel moulds and increase their sustainability. The spindle speed (rpm), the depth of cut (mm), and the feed rate (mm/rev) are considered as input variables for process optimization, and the experiments are performed on mild steel grade 60. It is deduced that the combination of a spindle speed of 800 rpm, feed rate of 10 mm/rev and depth of cut of 0.5 mm is the best case in case of minimum surface roughness, which leads to sustainable products. It is also deduced from ANOVA, that the spindle speed is a factor that affects the surface roughness of mild steel products, while the feed rate turns out to be insignificant.

scholarly journals Fabricating Different Laminate Composites by Manual Layup and Estimating the Optimum Parameters for CNC Milling Machine

2020 ◽  
Vol 23 (4) ◽  
pp. 388-396
Author(s):  
Ghadak M. Alkhafaji ◽  
Fathi A. Alshammaa ◽  
Enas A. Khalid
Keyword(s):  
Carbon Fiber ◽  
Epoxy Resin ◽  
Polyester Resin ◽  
Fiber Composite ◽  
Common Element ◽  
Depth Of Cut ◽  
Milling Machine ◽  
Cnc Milling ◽  
Laminate Composites ◽  
Cnc Milling Machine

In this paper the ability of fabricating laminate composites by manual layup was discussed. Heating method was used to manufacture the composites; heat was applied to approximately 12 hours with specific heat temperature. There were four types of laminate composites fabricated and studied in this research, containing Aluminum alloy 6061 as the common element in all types, two types of fibers; woven Carbon fiber with two different orientations: ±45°, ±60°, random fiberglass and with two types of resin; epoxy resin and polyester resin. Different types of composites were made to determine the effect of CNC milling machine to the measured surface roughness and for specified parameters. The weight fraction ratio of the fibers is 37%, polymer is 34% and 29% for Aluminum. The parameters selected are spindle speed, feed rate and depth of cut. The L9 Taguchi orthogonal arrays, signal to noise (S/N) ratio and analysis of variance (ANOVA) are selected to determine the effect of these parameters; it was analyzed by MINITAB 17 program. The results showed that the parameter were significant more to the epoxy resin specimens than polyester resin specimens. The optimal milling parameters for good surface finish for Aluminum – Carbon fiber composite are at 3000RPM, 1200mm/min, 1.2mm, and for Aluminum – Fiberglass composite are 5000RPM, 1800 mm/min, 2.0mm.

A Study on CAD/CAM Application in CNC Milling Using Industrial Clay

2015 ◽  
Vol 761 ◽  
pp. 32-36
Author(s):  
Nurul Wahieda Muhamad Bustaman ◽  
Mohd Salman Abu Mansor
Keyword(s):  
Low Cost ◽  
Machining Parameters ◽  
Milling Machine ◽  
Design Phase ◽  
Cnc Milling ◽  
Clay Sample ◽  
Machining Time ◽  
Cnc Milling Machine ◽  
Cad Cam ◽  
The Difference

Throughout the production process, improper planning and exploitation of the CAD/CAM system leads to the low level utilization of the CNC milling machine. In product design, tangible prototype is fabricated using CAD/CAM techniques in the design phase to analyse and modify the product before actual production. In this research, industrial clay is used as the prototype material. The objectives of the study are to investigate the machining parameters of industrial clay using the CNC milling machine and to apply the CAD/CAM system in producing a clay sample part via the CNC milling machine. Using uncomplicated and low cost setup for the fabrication method, an industrial clay sample part is prepared in the CAD/CAM system and shaped using the CNC milling machine. The difference between the simulated and the actual machining time of the machined part is analysed.

Optimizing the Machining Parameters in Glass Grinding Operation on the CNC Milling Machine for Best Surface Roughness

2010 ◽  
Vol 154-155 ◽  
pp. 721-726 ◽  
Author(s):  
Mohd Sayuti ◽  
Ahmed Aly Diaa Mohammed Sarhan ◽  
Mohd Hamdi Bin Abd Shukor
Keyword(s):  
Surface Roughness ◽  
Machining Process ◽  
Depth Of Cut ◽  
Response Analysis ◽  
Machining Parameters ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Machine ◽  
Cnc Milling Machine ◽  
Tool Diameter

Glass is one of the most difficult materials to be machined due to its brittle nature and unique structure such that the fracture is often occurred during machining and the surface finish produced is often poor. CNC milling machine is possible to be used with several parameters making the machining process on the glass special compared to other machining process. However, the application of grinding process on the CNC milling machine would be an ideal solution in generating special products with good surface roughness. This paper studies how to optimize the different machining parameters in glass grinding operation on CNC machine seeking for best surface roughness. These parameters include the spindle speed, feed rate, depth of cut, lubrication mode, tool type, tool diameter and tool wear. To optimize these machining parameters in which the most significant parameters affecting the surface roughness can be identified, Taguchi optimization method is used with the orthogonal array of L8(26). However, to obtain the most optimum parameters for best surface roughness, the signal to noise (S/N) response analysis and Pareto analysis of variance (ANOVA) methods are implemented. Finally, the confirmation test is carried out to investigate the improvement of the optimization. The results showed an improvement of 8.91 % in the measured surface roughness.

scholarly journals Machining Parameter Optimization of EVA Foam Orthotic Shoe Insoles

2020 ◽  
Vol 10 (3) ◽  
pp. 179-190
Author(s):  
Paulus Wisnu Anggoro ◽  
Abet Adhy Anthony ◽  
Mohammad Tauviqirrahman ◽  
Jamari ◽  
Athanasius Priharyoto Bayuseno ◽  
...  
Keyword(s):  
Tool Path ◽  
Ethylene Vinyl Acetate ◽  
Machining Parameters ◽  
Cnc Milling ◽  
Machining Time ◽  
Cnc Milling Machine ◽  
Step Over ◽  
Machining Parameter ◽  
Shoe Insoles ◽  
Eva Foam

In this study, ethylene-vinyl acetate (EVA) foam orthotic shoe insoles with different surface roughnesses (Ra) are investigated in terms of CNC milling strategy. Based on a hybrid Taguchi-response surface methodology (TM-RSM) approach, machining parameters, including tool path strategy, spindle speed, feed rate, and step over, as well as material hardness, are of particular interest. The main aim of this work is to develop mathematical models and determine the optimum machining parameters. Experiments are conducted on a CNC milling machine with a standard milling cutter and run under dry coolants. The optimal conditions are established based on TM and then used to determine the optimum values in the RSM modeling. The main finding of the present work is that there are significant improvements in the Ra, by up 0.24% and 4.13%, and machining time, by up 0.43% and 0.41%, obtained with TM-RSM in comparison to TM analysis.

scholarly journals The quality of MDF workpieces machined in CNC milling machine in cutting speeds, feedrate, and depth of cut

Meccanica ◽  
2015 ◽  
Vol 50 (12) ◽  
pp. 2899-2906 ◽  
Author(s):  
Priscila Roel De Deus ◽  
Manoel Cleber de Sampaio Alves ◽  
Fabio Henrique Antunes Vieira
Keyword(s):  
Depth Of Cut ◽  
Milling Machine ◽  
Cnc Milling ◽  
Cnc Milling Machine ◽  
Cutting Speeds
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