A Hybrid Analytical, Solid Modeler and Feature-Based Methodology for Extracting Tool-Workpiece Engagements in Turning

2005 ◽  
Author(s):  
Jing Zhou ◽  
Derek Yip-Hoi ◽  
Xuemei Huang
Keyword(s):  
Analytical Solution ◽  
Critical Points ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Efficient Computation ◽  
Virtual Machining ◽  
Machining System ◽  
Feature Based ◽  
Solid Modeler

In order to optimize turning processes cutting forces need to be accurately predicted. This in turn requires accurate extraction of the geometry of tool-workpiece engagements (TWE) at critical points during machining. TWE extraction is challenging because the in-process workpiece geometry is continually changing as each tool pass is executed. This paper describes research on a hybrid analytical, solid modeler and feature-based methodology for extracting TWEs generated during general turning. While a pure solid modeler based solution can be developed it will be shown that because of the ability to capture different cutting tool inserts with similar geometry and to model the process in 2D, an analytical solution can be used instead of the solid modeler in many instances. This leads to more efficient computation during extraction. Further, by identifying features in the removal volumes where the engagement conditions are not changing or changing predictably additional enhancements in the efficiency of the TWE extraction can be achieved. The methodology developed will be demonstrated in extracting engagements for a typical industrial component. TWE extraction is one component in a Virtual Machining system currently under development.

A Hybrid Analytical, Solid Modeler and Feature-Based Methodology for Extracting Tool-Workpiece Engagements in Turning

2007 ◽  
Vol 7 (3) ◽  
pp. 192-202 ◽  
Author(s):  
Jing Zhou ◽  
Derek Yip-Hoi ◽  
Xuemei Huang
Keyword(s):  
Analytical Solution ◽  
Critical Points ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Critical Component ◽  
Turning Process ◽  
Boolean Operations ◽  
Feature Based ◽  
Solid Modeler ◽  
Turning System

In order to optimize turning processes, cutting forces need to be accurately predicted. This in turn requires accurate extraction of the geometry of tool-workpiece engagements (TWE) at critical points during machining. TWE extraction is challenging because the in-process workpiece geometry is continually changing as each tool pass is executed. This paper describes research on a hybrid analytical, solid modeler, and feature-based methodology for extracting TWEs generated during general turning. Although a pure solid modeler-based solution can be applied, it will be shown that because of the ability to capture different cutting tool inserts with similar geometry and to model the process in 2D, an analytical solution can be used instead of the solid modeler in many instances. This solution identifies features in the removal volumes, where the engagement conditions are not changing or changing predictably. This leads to significant reductions in the number of Boolean operations that are executed during the extraction of TWEs and associated parameters required for modeling a turning process. TWE extraction is a critical component of a virtual turning system currently under development.

Geometric Modeling of Cutter/Workpiece Engagements in 3-Axis Milling Using Polyhedral Models

2007 ◽  
Author(s):  
Eyyup Aras ◽  
Derek Yip-Hoi
Keyword(s):  
Cutting Forces ◽  
Geometric Modeling ◽  
Tool Path ◽  
Cutting Tool ◽  
Milling Process ◽  
Mapping Technique ◽  
Depth Of Cut ◽  
Modeling Methodology ◽  
Machining System ◽  
Engagement Angle

Modeling the milling process requires cutter/workpiece engagement (CWE) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. This geometry defines the instantaneous intersection boundary between the cutting tool and the in-process workpiece at each location along a tool path. This paper presents components of a robust and efficient geometric modeling methodology for finding CWEs generated during 3-axis machining of surfaces using a range of different types of cutting tool geometries. A mapping technique has been developed that transforms a polyhedral model of the removal volume from Euclidean space to a parametric space defined by location along the tool path, engagement angle and the depth-of-cut. As a result, intersection operations are reduced to first order plane-plane intersections. This approach reduces the complexity of the cutter/workpiece intersections and also eliminates robustness problems found in standard polyhedral modeling and improves accuracy over the Z-buffer technique. The CWEs extracted from this method are used as input to a force prediction model that determines the cutting forces experienced during the milling operation. The reported method has been implemented and tested using a combination of commercial applications. This paper highlights ongoing collaborative research into developing a Virtual Machining System.

Geometric Modeling of Cutter/Workpiece Engagements in Three-Axis Milling Using Polyhedral Representations

2008 ◽  
Vol 8 (3) ◽  
Author(s):  
Eyyup Aras ◽  
Derek Yip-Hoi
Keyword(s):  
Cutting Forces ◽  
Geometric Modeling ◽  
Tool Path ◽  
Cutting Tool ◽  
Milling Process ◽  
Mapping Technique ◽  
Depth Of Cut ◽  
Modeling Methodology ◽  
Machining System ◽  
Engagement Angle

Modeling the milling process requires cutter/workpiece engagement (CWE) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. This geometry defines the instantaneous intersection boundary between the cutting tool and the in-process workpiece at each location along a tool path. This paper presents components of a robust and efficient geometric modeling methodology for finding CWEs generated during three-axis machining of surfaces using a range of different types of cutting tool geometries. A mapping technique has been developed that transforms a polyhedral model of the removal volume from the Euclidean space to a parametric space defined by the location along the tool path, the engagement angle, and the depth of cut. As a result, intersection operations are reduced to first order plane-plane intersections. This approach reduces the complexity of the cutter/workpiece intersections and also eliminates robustness problems found in standard polyhedral modeling and improves accuracy over the Z-buffer technique. The CWEs extracted from this method are used as input to a force prediction model that determines the cutting forces experienced during the milling operation. The reported method has been implemented and tested using a combination of commercial applications. This paper highlights ongoing collaborative research into developing a virtual machining system.

A Feature-Based Approach for Cutter/Workpiece Engagement Calculation in 2-1/2D End Milling

2006 ◽  
Author(s):  
Jue Wang ◽  
Derek Yip-Hoi
Keyword(s):  
Process Modeling ◽  
Cutting Forces ◽  
End Milling ◽  
Process Models ◽  
Machining Process ◽  
Geometric Invariant ◽  
Machining Features ◽  
Virtual Machining ◽  
Feature Based ◽  
Intersection Geometry

Machining process modeling requires cutter/workpiece engagement geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. Solid modelers can be used to perform these calculations by executing intersection operations between cutter and workpiece surfaces at successive cutter locations. These operations utilize parametric surface/surface intersection (SSI) algorithms. For the large number of engagements that can occur in machining a complicated workpiece this can be a time-consuming and sometimes unreliable process. In this paper, in-process machining features are introduced into machining process modeling for 2 1/2 D end milling, and a feature based approach is presented for addressing the computational complexity and robustness issues in the cutter/workpiece engagement calculations. Geometric Invariant (giF) and Form Invariant Machining Features (fiF) are modeled to help represent engagement conditions analytically. Volume decomposition and composition algorithms are described that extract these two types of machining features from the removal volumes generated at each tool pass. Cutter/workpiece engagements can be analytically extracted from giFs and fiFs without applying repetitive SSI operations. This paper presents one part of ongoing collaborative research into developing Virtual Machining Systems. The engagement conditions that are found are inputs to machining process models that identify cutting forces, predict stability and that optimize the process.

Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

2020 ◽  
Vol 997 ◽  
pp. 85-92
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
Abdullah Yassin ◽  
Shahrol Mohamaddan ◽  
Syaiful Anwar Rajaie ◽  
Muhammad Isyraf Mazlan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Tool Performance

One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

scholarly journals Stability analysis for a single-point cutting tool deflection in turning operation

2019 ◽  
Vol 11 (6) ◽  
pp. 168781401985318
Author(s):  
Amon Gasagara ◽  
Wuyin Jin ◽  
Angelique Uwimbabazi
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Tool ◽  
Single Point ◽  
Three Dimensional ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Beam Model ◽  
Tool Deflection

In this article, a new model of regenerative vibrations due to the deflection of the cutting tool in turning is proposed. The previous study reported chatter as a result of cutting a wavy surface of the previous cut. The proposed model takes into account cutting forces as the main factor of tool deflection. A cantilever beam model is used to establish a numerical model of the tool deflection. Three-dimensional finite element method is used to estimate the tool permissible deflection under the action of the cutting load. To analyze the system dynamic behavior, 1-degree-of-freedom model is used. MATLAB is used to compute the system time series from the initial value using fourth-order Runge–Kutta numerical integration. A straight hard turning with minimal fluid application experiment is used to obtain cutting forces under stable and chatter conditions. A single-point cutting tool made from high-speed steel is used for cutting. Experiment results showed that for the cutting parameters above 0.1mm/rev feed and [Formula: see text]mm depth of cut, the system develops fluctuations and higher chatter vibration frequency. Dynamic model vibration results showed that the cutting tool deflection induces chatter vibrations which transit from periodic, quasi-periodic, and chaotic type.

scholarly journals The Possibility of Applying Acoustic Emission and Dynamometric Methods for Monitoring the Turning Process

Materials ◽  
2020 ◽  
Vol 13 (13) ◽  
pp. 2926 ◽  
Author(s):  
Krzysztof Dudzik ◽  
Wojciech Labuda
Keyword(s):  
Acoustic Emission ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Radial Force ◽  
Diagnostic Methods ◽  
304L Stainless Steel ◽  
Turning Process ◽  
Physical Acoustics ◽  
Machined Surface ◽  
Feed Force

Ensuring optimal turning conditions has a huge impact on the quality and properties of the machined surface. The condition of the cutting tool is one of the factors to achieve this goal. In order to control its wear during the turning process, monitoring was used. In this study, the acoustic emission method and measure of cutting forces during turning were used for monitoring that process. The research was carried out on a universal lathe center (CU500MRD type) using a Kistler dynamometer with assembled removable insert CCET09T302R-MF by DIJET Industrial CO., LTD. A dynamometer allows to measure forces Fx (radial force), Fy (feed force) and Fz (cutting force). The turning process was performed on a shaft with 60 mm diameter made of 304L stainless steel. The AE research was carried at Physical Acoustics Corporation with the kit that includes: recorder USB AE Node, preamplifier, AE-sensor VS 150M and computer with dedicated software used for recording and analyzing AE data. The aim of this paper is to compare selected diagnostic methods: acoustic emission and cutting forces measurement for monitoring wear of cutting tool edge. Analysis of the research results showed that both selected methods of monitoring the turning process allowed the determination of the beginning of the tool damage process.

scholarly journals Analysis of chip formation and cutting forces in end milling AISI D2 tool steel with different cutting tool geometries

2018 ◽  
Vol 178 ◽  
pp. 01016
Author(s):  
Irina Beşliu ◽  
Dumitru Amarandei ◽  
Delia Cerlincă
Keyword(s):  
Cutting Force ◽  
Tool Steel ◽  
Chip Formation ◽  
Cutting Forces ◽  
Cutting Tool ◽  
End Milling ◽  
Great Influence ◽  
Tool Geometry ◽  
Aisi D2 ◽  
Aisi D2 Tool Steel

The purpose of this study was to investigate and establish the correlations between milling tool geometry, cutting conditions, as input factors and the cutting forces variations and chips formation, as output factors when end milling of AISI D2 tool steel. The experiments were carried out using a Taguchi design array. The chip shape and microstructure and cutting force components were analyzed. The results of the study show that the cutting tool geometry has a great influence over segmented chip formation mechanism and cutting force levels.

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