scholarly journals Modeling and Analysis of Five-Axis Milling Configurations and Titanium Alloy Surface Topography

2016 ◽  
Vol 138 (6) ◽  
Author(s):  
David Prat ◽  
Guillaume Fromentin ◽  
Gérard Poulachon ◽  
Emmanuel Duc
Keyword(s):  
Titanium Alloy ◽  
Surface Topography ◽  
Geometrical Model ◽  
Cutting Conditions ◽  
Modeling And Analysis ◽  
Good Surface ◽  
Good Surface Finish ◽  
Five Axis ◽  
Complex Parts ◽  
Location Point

Five-axis milling with a ball-end cutter is commonly used to generate a good surface finish on complex parts, such as blades or impellers made of titanium alloy. The five-axis milling cutting process is not straight forward; local cutting conditions depend a lot on the geometrical configuration relating to lead and tilt angles. Furthermore, the surface quality is greatly affected by the cutting conditions that define the milling configuration. This study presents a geometrical model of five-axis milling in order to determine the effective cutting conditions, the milling mode, and the cutter location point. Subsequently, an analysis of surface topography is proposed by using the geometrical model, local criteria, and a principle component analysis of experimental data. The results show the effects of local parameters on the surface roughness, in relation to the lead and tilt angles.

Adaptive Interpolation of Tool Posture Vector in Five-Axis Flank Milling

2012 ◽  
Vol 217-219 ◽  
pp. 2706-2710
Author(s):  
Jun Feng Tian ◽  
Hu Lin ◽  
Zhuang Yao ◽  
Jie Li ◽  
Jin Gang Yu ◽  
...  
Keyword(s):  
Cutting Conditions ◽  
Flank Milling ◽  
Interpolation Algorithm ◽  
Tolerance Range ◽  
Adaptive Interpolation ◽  
Optimum Cutting ◽  
Tool Posture ◽  
Simulation Results ◽  
Five Axis ◽  
Complex Parts

Five-axis flank milling is an important machining technique, especially in machining of complex parts. Tool posture vector can change easily using two axes of rotation to achieve optimum cutting conditions. However, the tool posture vector may change beyond the interpolation plane. This will result in overcut or undercut. In this paper, an adaptive interpolation algorithm of tool posture vector is proposed. In the proposed algorithm, the commanded feedrate for linear axis is kept constant for most time and adaptively adjusted to confine the chord error within a specified tolerance range during the interpolation process. The tool posture vector changes in the interpolation plane with a constant rotation degree. Simulation results from example are provided to verify the feasibility and advantages of the proposed scheme.

Modeling and Analysis of Cold Drawing Process

2017 ◽  
pp. 40-53 ◽  
Author(s):  
Praveen Kumar Loharkar ◽  
Mohan Kumar Pradhan
Keyword(s):  
Process Analysis ◽  
Cold Drawing ◽  
Drawing Process ◽  
Element Analysis ◽  
Modeling And Analysis ◽  
Good Surface ◽  
Superior Mechanical Properties ◽  
Good Surface Finish ◽  
State Of Research ◽  
Tools And Techniques

Products of cold drawing process are extensively used due to their characteristics such as very good surface finish, close dimensional control and superior mechanical properties. Therefore, this process has drawn attention of several researchers over the years. The chapter describes the state of research scenario in the field of cold drawing process analysis with a focus on various parameters and methods involved in its study. Work carried out in this context is described briefly along with the steps to carry out finite element analysis. It has also accounted for methods to design experiments and to optimize the process parameters. Upon reading this chapter, the reader would get acquainted with various aspects of cold drawing process modeling and scope for further research. With the help of fundamental knowledge of process and systematic application of the available tools and techniques, the reader would be equipped with the knowledge to work on related industrial problems and enhance process capability by applying soft computing techniques in process optimization.

CONTINUOUS-CAST 45-12 DUCTILE IRON

Alloy Digest ◽  
1989 ◽  
Vol 38 (4) ◽  
Keyword(s):  
Continuous Casting ◽  
Ductile Iron ◽  
Heat Treating ◽  
Grain Structure ◽  
Continuous Cast ◽  
Good Surface ◽  
Fine Grain ◽  
High Speeds ◽  
Good Surface Finish ◽  
Iron Grade

Abstract Ductile Iron grade 45-12 produced by continuous casting has consistent density and fine grain structure. It is the softest of the regular grades of ductile iron and it machines at high speeds with good surface finish. This datasheet provides information on composition, physical properties, microstructure, hardness, elasticity, and tensile properties. It also includes information on heat treating, machining, and joining. Filing Code: CI-58. Producer or source: Federal Bronze Products Inc..

Research on Chamfer Software of Complex Parts

2013 ◽  
Vol 631-632 ◽  
pp. 1335-1341
Author(s):  
Shi Yong ◽  
Wen Tao Liu
Keyword(s):  
3D Model ◽  
Tool Path ◽  
Machining Parameters ◽  
Cad Cam ◽  
Programming Software ◽  
A Chain ◽  
Definition Of ◽  
Complex Parts ◽  
Cam Software ◽  
Location Point

In order to meet the needs of enterprises for chamfering complex parts, based on the customization of commercial CAD/CAM software, chamfer programming software is developed. According to user’s machining demands for a part, a chain of edges of a part is extracted from its 3D model. With preprocessing of the chain of edges, the continuity of the chain is estimated, and the start and end point of those edges are automatic obtained. Furthermore, with human-machine dialogue, machining parameters is set by users. By definition of the primary and secondary surfaces of the chain of edges, and interpolation of the edges, the positions of cutter location point and postures of cutter are calculated. Finally the interference of tool path is checked, and tool path is simulated. The software solves the programming problem of chamfering complex parts.

The “Lost Wax” Process of Precision Casting

1950 ◽  
Vol 162 (1) ◽  
pp. 66-74 ◽  
Author(s):  
J. S. Turnbull
Keyword(s):  
Gas Turbine ◽  
Turbine Blades ◽  
Casting Process ◽  
Alternative Methods ◽  
Casting Technique ◽  
Gas Turbine Blades ◽  
Precision Casting ◽  
Good Surface ◽  
Wax Pattern ◽  
Good Surface Finish

The paper describes a casting process which differs from standard foundry practice in that it uses a wax pattern in a high refractory one-piece mould to produce metal castings with a good surface finish to an accuracy of ±0·002 inch. The process involves making a master pattern in either hard wood or metal, relating it to a soft metal die by precision casting technique, and then the production of wax patterns from the die on an injection machine. Finally, the wax patterns are invested in refractory moulds, the wax is melted out, the mould baked, and the metal component is cast. The “lost wax” process is advantageous in cases where ( a) the metal is unmachinable, or ( b) where the component is of an unmachinable shape, or ( c) where production by other methods takes too long. One of the most common applications is in the manufacture of gas-turbine blades. The tool costs are relatively low compared to the costs involved in alternative methods of manufacture, the die cost being a function of the number of castings required. The production of cheap castings is necessarily dependent on the scrap percentage being kept to a minimum; at present the scrap from the manufacture of gas-turbine blades is less than 30 per cent, and the author surmises that it would not be unreasonable to expect it to be less than 10 per cent in two years' time.

Manufacturability of Aircraft Winglet for Wind Tunnel Testing

2015 ◽  
Vol 830-831 ◽  
pp. 100-103
Author(s):  
L. Gopinath ◽  
S. Ravishankar
Keyword(s):  
Wind Tunnel ◽  
Metal Cutting ◽  
Tool Path ◽  
Cutting Parameters ◽  
Cnc Machining ◽  
Depth Of Cut ◽  
Manufacturing Strategy ◽  
Thin Sections ◽  
Good Surface ◽  
Good Surface Finish

The form, shape and dimensions of the scaled down winglet model become small and thin bringing complexity to manufacturing. The trailing edge tapers to a thickness varying from 0.065mm to 0.099mm along its length. The mounting portion of the winglet is provided with a close tolerance having a slot gap of 5mm and a depth of 35 mm with an angle. Additionally, wind tunnel models require good surface finish on the aerodynamic surfaces and this involves adopting a manufacturing strategy with a control over on the metal cutting parameters to be implemented on a three axes CNC machining centre. The winglet surface is divided into segments in order to handle the cutting forces on the varying aerodynamic cross section. Various metal cutting parameters such as tool path, cutter diameter, feed rate, depth of cut, spindle speed, etc., are evaluated by monitoring segments where the metal cutting is carried out [1] and flow of chips observed. Fixtures and lugs are planned effectively to accommodate the machining of the angular slot in a three axes machining centre itself. Routing of operations to handle the varying thin sections and realisation of the close tolerance slot has enabled a reliable manufacturing approach in an economical way.

scholarly journals Machined Surface Topography Investigation in Turning of Titanium Alloy (Ti-6al-4v) Using Steam as A Coolant

2015 ◽  
Vol 12 (2) ◽  
pp. 104-107
Author(s):  
Afaqahmed Jamadar ◽  
Vilas Shinde ◽  
Muhammedumar Jamadar ◽  
Javed Kazi
Keyword(s):  
Titanium Alloy ◽  
Surface Topography ◽  
Machined Surface

scholarly journals Tribological Behavior and Analysis on Surface Roughness of CNC Milled Dual Heat Treated Al6061 Composites

2021 ◽  
Vol 2021 ◽  
pp. 1-14
Author(s):  
A. Bovas Herbert Bejaxhin ◽  
G.M. Balamurugan ◽  
S.M. Sivagami ◽  
K. Ramkumar ◽  
V. Vijayan ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Surface Roughness ◽  
Lower Surface ◽  
Cnc Machining ◽  
Depth Of Cut ◽  
Good Surface ◽  
Heat Treated ◽  
Good Surface Finish ◽  
Artificial Neural Network Ann ◽  
Machining Properties

Dual heat treatment (DHT) effect is analyzed using the machining of Al6061-T6 alloy, a readily available material for quickly finding the machining properties. The heat treatments are conducted twice over the specimen by the furnace heating before processing through CNC machining. The HSS and WC milling cutters are preferred for the diameter of 10 mm for the reviewed rotational speeds of 2000 rpm and 4000 rpm, and the constant depth of cut of 0.5 mm is chosen based on various reviews. Worthy roughness could be provided mostly by the influence of feed rates preferred here as 0.05 mm/rev and 0.1 mm/rev. The influencing factors are identified by the Taguchi, genetic algorithm (GA), and Artificial Neural Network (ANN) techniques and compared within it. The simulation finding also helps to clarify the relationship between influenced machining constraints and roughness outcomes of this project. The average values of heat treated and nonheat treated Al6061-T6 are compared and it is to be evaluated that 41% improvement is obtained with the lower surface roughness of 1.78975 µm and it shows good surface finish with the help of dual heat treatment process.

Experimental Investigations of the Machinability of Titanium Alloy TC4 with Different Hydrogen Contents

2011 ◽  
Vol 418-420 ◽  
pp. 1307-1311
Author(s):  
Jun Hu ◽  
Yong Jie Bao ◽  
Hang Gao ◽  
Ke Xin Wang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Hydrogen Content ◽  
Experimental Results ◽  
Cutting Conditions ◽  
Experimental Investigations ◽  
Cutting Condition ◽  
The Given

The experiments were carried out in the paper to investigate the effect of adding hydrogen in titanium alloy TC4 on its machinability. The hydrogen contents selected were 0, 0.25%, 0.49%, 0.63%, 0.89% and 1.32%, respectively. Experiments with varing hydrogen contents and cutting conditions concurrently. Experimental results showed that the cutting force of the titanium alloy can be obviously reduced and the surface roughness can be improved by adding appropriate hydrogen in the material. In the given cutting condition, the titanium alloy TC4 with 0.49% hydrogen content showed better machinability.

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