Motion Tuning Method of Linear Axes and Rotary Axis Under a Constant Cutting Speed Vector at End-Milling Point With a Five-Axis Controlled Machining Center

2015 ◽  
Author(s):  
Takamaru Suzuki ◽  
Takakazu Ikegami ◽  
Takayuki Akai ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
...  
Keyword(s):  
Surface Quality ◽  
End Milling ◽  
High Surface ◽  
Cutting Speed ◽  
Surface Shape ◽  
Feed Speed ◽  
Shape Error ◽  
Rotary Axis ◽  
Machining Center ◽  
Five Axis

Recently It is difficult to maintain the high surface quality ingenerating curved surface shape under five-axis controlled end-milling. In this study, we aimed at maintaining feed speed vector at milling point by controlling two linear axes and a rotary axis with a five-axis machining center, to improve machined surface quality and suggested a method for solving shape error of machined workpiece considering differences of three axes’s sarvo characteristics. As the results, it could be seen that shape error greatly decreased based on the proposed method.

Improved Accuracy of a Machining Tool With a Constant Cutting Speed Vector and Outside Approach Path

2020 ◽  
Author(s):  
Takamaru Suzuki ◽  
Shoya Iwama ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Takakazu Ikegami ◽  
...  
Keyword(s):  
Three Dimensional ◽  
Cutting Speed ◽  
Feed Speed ◽  
Actual Process ◽  
Shape Error ◽  
Direct Drive ◽  
Wireless Internet ◽  
Machined Surface ◽  
Machining Center ◽  
Five Axis

Abstract A five-axis machining center is equipped with a direct drive motor on a rotary axis and is capable of synchronous control, which makes it a feasible tool for quickly and accurately machining complicated three-dimensional surfaces such as propellers and hypoid gears. However, the accuracy of the machined shape and consistency of the freeform machined surface both need to be improved. We developed a method for maintaining the feed speed vector at the milling point by controlling three axes of the five-axis machining center (two linear and one rotary) to improve the quality of the machined surface considering differences in the servo characteristics of the three axes during the actual process. Experimental results showed that using the proposed method with an outside approach path for the machining tool greatly reduced the shape error. The effectiveness of the proposed method was verified by using a wireless Internet of Things holder to monitor the machining force.

scholarly journals Improved Method for Synchronizing Motion Accuracy of Linear and Rotary Axes Under Constant Feed Speed Vector at End Milling Point – Investigation of Motion Error Under NC-Commanded Motion –

2019 ◽  
Vol 13 (5) ◽  
pp. 679-690 ◽  
Author(s):  
Takamaru Suzuki ◽  
Kazuki Yoshikawa ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Takakazu Ikegami ◽  
...  
Keyword(s):  
End Milling ◽  
Research Work ◽  
Free Form ◽  
Machining Accuracy ◽  
Feed Speed ◽  
Shape Error ◽  
Control Coefficient ◽  
Machined Surface ◽  
Motion Error ◽  
Rotary Axis

A 5-axis machining center (5MC) is noted for its synchronous control capability, making it a feasible tool for quickly and accurately machining complicated three-dimensional surfaces such as propellers and hypoid gears as it is equipped with a direct-drive (DD) motor in the rotary axis. The current research work identified the necessity of improving both the accuracy of the machined shape and the consistency of the free-form machined surface. A method for maintaining the feed speed vector at the milling point by controlling two linear axes and the rotary axis of a 5MC to improve the quality of the machined surface was investigated. Additionally, a method was proposed for reducing the shape error of machined workpieces by considering differences in the servo characteristics of the three axes. The shape error was significantly reduced by applying the proposed method using a precedent control coefficient determined via calculations. To maintain the feed speed vector at the milling point in the machining of complex shapes, rapid velocity change in each axis is often required, leading to inaccuracy caused by torque saturation at a DD motor in the rotary axis. The results of this study indicate that torque saturation can be evaluated via simulation and that the machining accuracy and consistency can be improved by accounting for these errors using the proposed precedent control coefficient method.

Investigation of Motion Control of Liner Axes and a Rotary Axis Under Constant Feed Speed Vector at Milling Point With a Five-Axis Machining Center

2013 ◽  
Author(s):  
Yuma Maruyama ◽  
Takayuki Akai ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama ◽  
Keiji Ogawa
Keyword(s):  
Surface Roughness ◽  
Present Report ◽  
Sudden Change ◽  
Machining Accuracy ◽  
Feed Speed ◽  
Motion Error ◽  
Rotary Axis ◽  
Machining Center ◽  
Five Axis ◽  
Cutting Point

Recently, a novel manufacturing technology has spread out with a five-axis machining center. It is especially important to keep the surface roughness on an entire machined surface constant. Thus, we proposed a novel method for maintaining a constant feed speed vector at the cutting point between the end-mill tool and the workpiece surface by controlling two linear axes and a rotary axis with a five-axis machining center. In the present report, we focused on machining the combined inner and outer radius curvature and investigating the influence of synchronous control error between the linear axes and rotary axis on the machining accuracy and surface roughness. As a result, we determined that it is possible to suppress sudden change in the synchronous motion error by accurately aligning the motion direction of the linear and rotary axes and the feed speed vector at milling point at the contact point of the inner and outer circles.

scholarly journals Investigation on the Surface Quality Obtained during Trochoidal Milling of 6082 Aluminum Alloy

Machines ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 75
Author(s):  
Nikolaos E. Karkalos ◽  
Panagiotis Karmiris-Obratański ◽  
Szymon Kurpiel ◽  
Krzysztof Zagórski ◽  
Angelos P. Markopoulos
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Process Parameters ◽  
Manufacturing Industry ◽  
High Surface ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Surface Quality ◽  
Trochoidal Milling

Surface quality has always been an important goal in the manufacturing industry, as it is not only related to the achievement of appropriate geometrical tolerances but also plays an important role in the tribological behavior of the surface as well as its resistance to fatigue and corrosion. Usually, in order to achieve sufficiently high surface quality, process parameters, such as cutting speed and feed, are regulated or special types of cutting tools are used. In the present work, an alternative strategy for slot milling is adopted, namely, trochoidal milling, which employs a more complex trajectory for the cutting tool. Two series of experiments were initially conducted with traditional and trochoidal milling under various feed and cutting speed values in order to evaluate the capabilities of trochoidal milling. The findings showed a clear difference between the two milling strategies, and it was shown that the trochoidal milling strategy is able to provide superior surface quality when the appropriate process parameters are also chosen. Finally, the effect of the depth of cut, coolant and trochoidal stepover on surface roughness during trochoidal milling was also investigated, and it was found that lower depths of cut, the use of coolant and low values of trochoidal stepover can lead to a considerable decrease in surface roughness.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

scholarly journals Improvement of machined accuracy under constant feed speed at milling point with a five axis controlled machining center considering approach path

2020 ◽  
Vol 86 (889) ◽  
pp. 20-00175-20-00175
Author(s):  
Takamaru SUZUKI ◽  
Shoya IWAMA ◽  
Toshiki HIROGAKI ◽  
Eiichi AOYAMA
Keyword(s):  
Feed Speed ◽  
Machining Center ◽  
Five Axis

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

Sensitivity Analysis of Error Motions and Geometric Errors in the Case of Sphere-Shaped Workpiece

2020 ◽  
Author(s):  
Zongze Li ◽  
Ryuta Sato ◽  
Keiichi Shirase
Keyword(s):  
Sensitivity Analysis ◽  
Machine Tools ◽  
End Milling ◽  
Geometric Errors ◽  
Machined Surface ◽  
Error Sources ◽  
Motion Error ◽  
Machining Center ◽  
Machining Errors ◽  
Five Axis

Abstract Motion error of machine tool feed axes influences the machined workpiece accuracy. However, the influences of each error sources are not identical; some errors do not influence the machined surface although some error have significant influences. In addition, five-axis machine tools have more error source than conventional three-axis machine tools, and it is very tough to predict the geometric errors of the machined surface. This study proposes a method to analyze the relationships between the each error sources and the error of the machined surface. In this study, a kind of sphere-shaped workpiece is taken as a sample to explain how the sensitivity analysis makes sense in ball-end milling. The results show that the method can be applied for the axial errors, such as motion reversal errors, to make it clearer to obverse the extent of each errors. In addition, the results also show that the presented sensitivity analysis is useful to investigate that how the geometric errors influence the sphere surface accuracy. It can be proved that the presented method can help the five-axis machining center users to predict the machining errors on the designed surface of each axes error motions.

Experimental Research of Effective Cutting Speed Influence on Surface Roughness in Ball End Milling of C45 Material with Hardness 34 HRC

2014 ◽  
Vol 657 ◽  
pp. 53-57 ◽  
Author(s):  
Sándor Ravai Nagy ◽  
Ioan Paşca ◽  
Mircea Lobonțiu ◽  
Mihai Banica
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Experimental Research ◽  
Inclination Angle ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Speed ◽  
Cnc Machine Tools ◽  
Machined Surface ◽  
Ball End Milling

Machining of Complex Concave or Convex Surfaces Requires the Use of Ball End Milling Cutters. Obtaining the Expected Surface Quality Compete Various Technological Factors which should be Taken into Account. Following the Machining of the Surface with Different Inclination Angles between the Cutting Tool Axes and the Machined Surface, Significant Changes of the Surface Roughness have been Observed. Based on the Tests Performed, we can Determine the Range of the Tool Inclination Angle, which is the Best for the Surface Quality. we have also Made a Correlation between the Cutting Speeds, Inclination Angle of the Cutting Tool Toward the Machined Surface for an Obtained Surface Quality. the Presented Results are Based on Experimental Research in Industrial Conditions by Using CNC Machine Tools with 5 Axes. the Tests have been Performed on the C45 Material, Heat Treated to 34HRC.

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