scholarly journals Eliminating the Effect of Uncertainties of Cutting Forces by Fuzzy Controller for Robots in Milling Process

2020 ◽  
Vol 10 (5) ◽  
pp. 1685 ◽  
Author(s):  
Khoi Bui Phan ◽  
Hai Thanh Ha ◽  
Sinh Vinh Hoang
Keyword(s):  
Differential Equations ◽  
Dynamic Model ◽  
Cutting Forces ◽  
Fuzzy Controller ◽  
Driving Forces ◽  
Milling Process ◽  
Industrial Robots ◽  
Machining Process ◽  
Depth Of Cut ◽  
Input And Output

This study presents a method of controlling robots based on fuzzy logic to eliminate the effect of uncertainties that are generated by the cutting forces in milling process. The common method to control industrial robots is based on the robot dynamic model and the differential equations of motion to compute the control values. The quantities in the differential equations of the motion of robots are complex and difficult to determine fully and accurately. The interaction forces between the cutting tool and the workpiece are the cutting forces, which are generated during the machining process. It is difficult to calculate the cutting force because it depends on many factors such as material of the machining part, depth of cut, feed rate, etc. This article presents the fuzzy rule system and the selection of the physical value domain of input and output variables of the fuzzy controller. The fuzzy rules are applied in this article to allow us to compute the driving forces based on the errors of input and output signals of the joint positions and velocities, thereby avoiding the calculation of cutting forces. This article shows the simulation results of the fuzzy controller and comparison with the results of the conventional controller when the dynamic model is assumed to be correctly determined. The achieved results are reliable and facilitate the research and application of a fuzzy controller to mechanical processing robots in general and milling machining in particular.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

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.

scholarly journals Chatter identification in milling of Inconel 625 based on recurrence plot technique and Hilbert vibration decomposition

2018 ◽  
Vol 148 ◽  
pp. 09003 ◽  
Author(s):  
Paweł Lajmert ◽  
Rafał Rusinek ◽  
Bogdan Kruszyński
Keyword(s):  
Stability Limit ◽  
Recurrence Plot ◽  
Milling Process ◽  
Machining Process ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Force Measurements ◽  
Stability Lobe ◽  
Theoretical Finding ◽  
The Stability

In the paper a cutting stability in the milling process of nickel based alloy Inconel 625 is analysed. This problem is often considered theoretically, but the theoretical finding do not always agree with experimental results. For this reason, the paper presents different methods for instability identification during real machining process. A stability lobe diagram is created based on data obtained in impact test of an end mill. Next, the cutting tests were conducted in which the axial cutting depth of cut was gradually increased in order to find a stability limit. Finally, based on the cutting force measurements the stability estimation problem is investigated using the recurrence plot technique and Hilbert vibration decomposition method.

Finite Element Analysis of a Frictionally Damped Slender Endmill

2012 ◽  
Author(s):  
Reza Madoliat ◽  
Sajad Hayati
Keyword(s):  
Finite Element ◽  
End Milling ◽  
Friction Stress ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Parameter Study ◽  
Bending Vibration ◽  
Element Analysis ◽  
Tool Axis

This paper primarily deals with suppression of chatter in end-milling process. Improving the damping is one way to achieve higher stability for machining process. For this purpose a damper is proposed that is composed of a core and a multi fingered hollow cylinder which are shrink fitted in each other and their combination is shrink fitted inside an axial hole along the tool axis. This structure causes a resisting friction stress during bending vibration. Using FEA-ANSYS the structure is simulated. Then a parameter study is carried out where the frequency response and the depth of cut are calculated and tabulated to obtain the most effective configuration. The optimal configuration of tool is fabricated and finite element results are validated using modal test. The results show a high improvement in performance of the tool with proposed damper. Good agreement between experiments and modeling is obtained.

Analysis of Force Shape Characteristics and Detection of Depth-of-Cut Variations in End Milling

2004 ◽  
Vol 127 (3) ◽  
pp. 454-462 ◽  
Author(s):  
Liuqing Yang ◽  
Richard E. DeVor ◽  
Shiv G. Kapoor
Keyword(s):  
Cutting Forces ◽  
Analytical Approach ◽  
End Milling ◽  
Milling Process ◽  
Depth Of Cut ◽  
End Mill ◽  
Shape Characteristics ◽  
Cutting Experiments ◽  
End Milling Process ◽  
Degree Of Overlap

This paper proposes an analytical approach to detect depth-of-cut variations based on the cutting-force shape characteristics in end milling. Cutting forces of a single-flute end mill are analyzed and classified into three types according to their shape characteristics. Cutting forces of a multiple-flute end mill are then classified by considering both the cutting types of the corresponding single-flute end mill and the degree of overlap of successive flutes in the cut. Force indices are extracted from the cutting forces and depth-of-cut variations are detected based on the changes of the force shape characteristics via the force indices in an end-milling process. The detection methodology is validated through cutting experiments.

Influence of the Cutting Parameters on the Cutting Forces of Carbon Steel

2002 ◽  
Author(s):  
Zulay Cassier ◽  
Patricia Mun˜oz-Escanola ◽  
Rolda´n Sa´nchez
Keyword(s):  
Carbon Steel ◽  
Cutting Forces ◽  
Low Cost ◽  
Cutting Parameters ◽  
Carbon Steels ◽  
Machining Process ◽  
Depth Of Cut ◽  
Nose Radius ◽  
Aisi 1045 ◽  
Alloy Steels

Plain carbon steels and alloy steels have a great application in the manufacturing process especially due to their characteristic of high machinability and low cost. The machining of these materials, the study of the cutting forces, and the power required for the cutting process is one of the most important parameters to be evaluated. The relationship between this parameter and the other cutting variables process is crucial for the optimization of the machining process. The results of this research are empirical expressions, obtained from the cutting parameters (tool nose radius, feed rate and depth of cut) and the influence of these parameters on the cutting forces for each carbon steel studied (AISI 1020, AISI 1045 and AISI 4340), as well as a general expression which includes the mechanical properties of these carbon steels. These results enable the user to predict cutting forces when using a turning process.

Optimization of Process Parameters for Cutting Force for Aluminium 7010 in CNC End Milling Process

2018 ◽  
Vol 10 (6) ◽  
Author(s):  
M. Kishanth ◽  
P. Rajkamal ◽  
D. Karthikeyan ◽  
K. Anand
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Optimization Of Process Parameters ◽  
Cnc End Milling ◽  
End Milling Process

In this paper CNC end milling process have been optimized in cutting force and surface roughness based on the three process parameters (i.e.) speed, feed rate and depth of cut. Since the end milling process is used for abrading the wear caused is very high, in order to reduce the wear caused by high cutting force and to decrease the surface roughness, the optimization is much needed for this process. Especially for materials like aluminium 7010, this kind of study is important for further improvement in machining process and also it will improve the stability of the machine.

Modeling & Analysis of End Milling Process Parameters Using Artificial Neural Networks

2014 ◽  
Vol 592-594 ◽  
pp. 2733-2737 ◽  
Author(s):  
G. Harinath Gowd ◽  
K. Divya Theja ◽  
Peyyala Rayudu ◽  
M. Venugopal Goud ◽  
M .Subba Roa
Keyword(s):  
Neural Networks ◽  
Artificial Neural Networks ◽  
Process Parameters ◽  
End Milling ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Artificial Neural ◽  
End Milling Process

For modeling and optimizing the process parameters of manufacturing problems in the present days, numerical and Artificial Neural Networks (ANN) methods are widely using. In manufacturing environments, main focus is given to the finding of Optimum machining parameters. Therefore the present research is aimed at finding the optimal process parameters for End milling process. The End milling process is a widely used machining process because it is used for the rough and finish machining of many features such as slots, pockets, peripheries and faces of components. The present work involves the estimation of optimal values of the process variables like, speed, feed and depth of cut, whereas the metal removal rate (MRR) and tool wear resistance were taken as the output .Experimental design is planned using DOE. Optimum machining parameters for End milling process were found out using ANN and compared to the experimental results. The obtained results provβed the ability of ANN method for End milling process modeling and optimization.

An Implementation of Analytical Boundary Simulation on Feedrate Scheduling during Semi-Finish Milling

2016 ◽  
Vol 851 ◽  
pp. 211-215
Author(s):  
Hendriko Hendriko
Keyword(s):  
Cutting Forces ◽  
Machining Process ◽  
Depth Of Cut ◽  
Force Model ◽  
Cutting Force Model ◽  
Feedrate Scheduling ◽  
Helical Angle ◽  
Result Show ◽  
Five Axis ◽  
Good Agreement

In five-axis milling, determining the continuously changing Cutter Workpiece Engagement (CWE) remains a challenge. All the feedrate calculation method that have been reported need a precise information about Cutter Workpiece Engagement. In this paper, the cut geometry was calculated using an analytical method called Analytical Boundary Simulation (ABS). This method was reported accurate and less expensive in term of calculation time. The cut geometry data was then used to calculate the instantaneous cutting forces. A new mechanistic force model was developed by taken into account the variation of axial depth of cut, the feedrate, the tool orientation, and the helical angle. Analytical boundary simulation and mechanisitic cutting force model were then used to optimize a semi finish machining process using feedrate scheduling. The applicability of the proposed method was verified experimentally and the result show that the calculated cutting forces of feedrate scheduling have a good agreement with those obtained from the experimental work.

Chatter Investigation in Titanium Milling

2014 ◽  
Vol 1019 ◽  
pp. 318-324
Author(s):  
Jean Claude Fwamba ◽  
Lerato Crescelda Tshabalala ◽  
Cebo Philani Ntuli ◽  
Isaac Tlhabadira
Keyword(s):  
Feed Rate ◽  
End Milling ◽  
Processing Condition ◽  
Weight Ratio ◽  
Dimensional Accuracy ◽  
Milling Process ◽  
Machining Process ◽  
Depth Of Cut ◽  
Machining Performance ◽  
Chatter Vibrations

<span><p align="LEFT"><span><span style="font-family: Times New Roman;" face="Times New Roman">Titanium and its alloys have been experiencing extensive development over the past few decades. They have found wide applications in the aerospace, biomedical and automotive industries owing to their good strength-to-weight ratio and high corrosion resistance. Machining performance is often limited by chatter vibrations at the tool-workpiece interface. Chatter is an abnormal tool behaviour which is one of the most critical problems in the machining process and must be avoided to improve the dimensional accuracy and surface quality of the finished product. This research aims at investigating chatter trends in the end milling process and to identify machine parameters that have effects on chatter during machining. The machine parameters investigated include axial feed rate, spindle revolute speed and depth of cut. In this research, experimental data was collected using sensors to analyze the existence of chatter vibrations on each processing condition. This research showed that the combination of the machine parameters, feed rate and spindle speed within certain proportions has an influence on machine vibrations during end milling and if not managed properly, may lead to chatter. </span></span></p> <p align="LEFT"></p>

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