scholarly journals Multi-Criteria Selection of the Optimal Parameters for High-Speed Machining of Aluminum Alloy Al7075 Thin-Walled Parts

Metals ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 1570
Author(s):  
Dejan Lukic ◽  
Robert Cep ◽  
Jovan Vukman ◽  
Aco Antic ◽  
Mica Djurdjev ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
High Speed ◽  
Tool Path ◽  
Dimensional Accuracy ◽  
Cutting Parameters ◽  
Optimal Level ◽  
Machining Parameters ◽  
Thin Walled ◽  
Machining Parameter ◽  
Selection Of

Thin-walled parts made of aluminum alloy are mostly used as structural elements in the aerospace, automobile, and military industries due to good homogeneity, corrosion resistance, and the excellent ratio between mechanical properties and mass. Manufacturing of these parts is mainly performed by removing a large volume of material, so it is necessary to choose quality machining parameters that will achieve high productivity and satisfactory quality and accuracy of machining. Using the Taguchi methodology, an experimental plan is created and realized. Based on its results and comparative analysis of multi-criteria decision making (MCDM) methods, optimal levels of machining parameters in high-speed milling of thin-walled parts made of aluminum alloy Al7075 are selected. The varying input parameters are wall thickness, cutting parameters, and tool path strategies. The output parameters are productivity, surface quality, dimensional accuracy, the accuracy of forms and surface position, representing the optimization criteria. Selection of the optimal machining parameter levels and their ranking is realized using 14 MCDM methods. Afterward, the obtained results are compared using correlation analysis. At the output, integrative decisions were made on selecting the optimal level and rank of alternative levels of machining parameters.

The Process Strategies of Mould High-Speed Machining and their Applications in the Environment of PowerMILL

2011 ◽  
Vol 188 ◽  
pp. 542-548 ◽  
Author(s):  
Jie Liu
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Whole Process ◽  
Machining Strategies ◽  
Selection Of

High-speed machining requires the support of high intelligent CAM software as well as customized machining strategies and properly selected machining parameters. Only by combining the two can the advantage of high-speed machining be made full use of. Compared to ordinary NC cutting, high-speed machining has special requirements for process strategies, CAM system and tool path. A complete tool path includes approaching/retracting tool, moving tool and tool path. Based on the above principles, a mould part is successfully processed using the PowerMILL software at the high-speed machining centre of DMG-DMU40T. The maximum hardness of the mould part is HRC50. There’s a 30 degree corner in the cavity with a transition radius of 3mm. The whole process can be divided into three stages: rough, semi-finish and finish machining and each stage involves the selection of tool path, the selection of tool, the selection of cutting parameters (including spindle speed, feed speed and depth of cut), and the application of PowerMILL specific machining methods (such as Race-line machining, rest roughing, automatic trochoidal machining, 3D offset finishing and etc).

Experiment and Analysis on Side Milling Deformation of Thin-Walled Workpieces Using Laddered Symmetrical Tool Path

2013 ◽  
Vol 710 ◽  
pp. 233-237
Author(s):  
Yong Qiang He
Keyword(s):  
Parameter Optimization ◽  
Tool Path ◽  
Cutting Parameters ◽  
Deformation Characteristics ◽  
Side Milling ◽  
Machining Center ◽  
Thin Walled ◽  
Aluminum 7075 ◽  
Machining Parameter ◽  
Deformation Error

The aluminum 7075 workpieces are machined on a vertical machining center KX650 using laddered symmetrical tool path. The deformation characteristics are studied under different cutting conditions. Different cutting parameters are changed one by one in side milling tests to find out their impact on deformation error. The analyzed result provides a solid basis for machining parameter optimization in side milling thin-walled workpieces.

Design of Database for High Speed Cutting of Difficult-to-Cut Materials

2012 ◽  
Vol 723 ◽  
pp. 337-342
Author(s):  
Li Juan Liu ◽  
Wen Ge Wu ◽  
Ming Lv
Keyword(s):  
High Speed ◽  
Tool Path ◽  
Cutting Parameters ◽  
Advanced Manufacturing ◽  
Machining Parameters ◽  
Selection Scheme ◽  
High Speed Cutting ◽  
Parameters Selection ◽  
Development Direction ◽  
Choice Method

High speed machining (HSM) is one of the main trends of cutting machinery and is an important development direction of advanced manufacturing technology. In our country, the relevant research of HSM database starts later, especially of the cutting of hardworking material, the actual machining and experiment on the machining technology and the machining parameters of HSM are few, the reasonable machining parameters selection scheme and the appropriate cutter choice method are lack. The paper established HSM database system of the hardworking material based on web to improve cutting efficiency. According to the different feed and cutting tool by the Web form, it gets the rational cutting parameters. And the system determines the tool-path planning by the manufacture HSM of hardworking material processing animation to simulate the high-speed milling. The results of inquiry as a Web page and let you get parameters of optimization, increases efficiency of factories.

Chatter Prediction Based on NC Physical Simulation in Machining Ti6Al4V Thin-Walled Components

2013 ◽  
Vol 395-396 ◽  
pp. 1008-1014
Author(s):  
Yu Li ◽  
Chao Sun
Keyword(s):  
Tool Path ◽  
Physical Simulation ◽  
Prediction Method ◽  
Cutting Parameters ◽  
Simulation Software ◽  
Cnc Machining ◽  
Machining Process ◽  
Chatter Stability ◽  
Chatter Prediction ◽  
Thin Walled

Chatter has been a problem in CNC machining process especially during machining thin-walled components with low stiffness. For accurately predicting chatter stability in machining Ti6Al4V thin-walled components, this paper establishes a chatter prediction method considering of cutting parameters and tool path. The fast chatter prediction method for thin-walled components is based on physical simulation software. Cutting parameters and tool path is achieved through the chatter stability lobes test and finite element simulation. Machining process is simulated by the physical simulation software using generated NC code. This proposed method transforms the NC physical simulation toward the practical methodology for the stability prediction over the multi-pocket structure milling.

Investigation and Modeling of Flag Generation in Honeycomb Sandwich Panel Machining

2018 ◽  
Author(s):  
Derek M. Yip-Hoi ◽  
David D. Gill
Keyword(s):  
Geometric Modeling ◽  
High Speed ◽  
Tool Path ◽  
Sandwich Panels ◽  
Cutting Parameters ◽  
Honeycomb Structures ◽  
Anisotropic Mechanical Properties ◽  
Honeycomb Sandwich ◽  
Low Stiffness ◽  
The Impact

Light weight honeycomb structures lend themselves to important applications in aerospace. These range from aerodynamic and structural components such as wing edges, flaps, rotor blades and engine cowlings, to aircraft interior structures such as overhead luggage bins, compartment liners, bulkheads and the monument structures found in galleys and lavatory areas. Often the honeycomb is formed into a composite ply sandwich with fiberglass face sheets bonded to the honeycomb core. These panels are cut to shape using CNC routers and specially designed cutting tools. However, the quality of the cuts generated even with these special tools leaves much to be desired. The low stiffness of the structure leads to imperfections such as fraying of the cut face sheet edges and the generation of flags along the cut honeycomb edge. These impact the ease of assembly and often require manually intensive reworking to mitigate. The cutting of honeycomb structures and sandwich panels is challenging due to low stiffness, anisotropic mechanical properties and a high proportion of interrupted cutting due to the air voids that are present. The cutting mechanics are not well understood at this time. This paper presents findings from the study of cutting of honeycomb sandwich panels using high speed videography and correlates these with results of geometric modeling of the engagement between the cutter and workpiece. The study includes the impact of the trajectory of the tool path through the cell structures on the generation of flagging. It also reports on the effects of two different cutting tool geometries and the introduction of a lead angle on the size and structure of the flags generated. These findings present the case for a research regime similar to the one completed for solid metals, into modeling the mechanics behind machining honeycomb structures. This will help manufacturers using these materials to make better choices in the tools, cutting parameters and machining strategies that they employ in their process planning.

scholarly journals Intelligent Selection of Machining Parameters in Multipass Turnings Using Firefly Algorithm

2014 ◽  
Vol 2014 ◽  
pp. 1-6 ◽  
Author(s):  
Abderrahim Belloufi ◽  
Mekki Assas ◽  
Imane Rezgui
Keyword(s):  
Production Cost ◽  
Firefly Algorithm ◽  
Optimization Technique ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Metal Parts ◽  
Multipass Turning ◽  
Optimal Cutting Parameters ◽  
Selection Of

Determination of optimal cutting parameters is one of the most important elements in any process planning of metal parts. In this paper, a new optimization technique, firefly algorithm, is used for determining the machining parameters in a multipass turning operation model. The objective considered is minimization of production cost under a set of machining constraints. The optimization is carried out using firefly algorithm. An application example is presented and solved to illustrate the effectiveness of the presented algorithm.

The HSM Intelligent Database System Based on Neural Networks

2011 ◽  
Vol 201-203 ◽  
pp. 162-166
Author(s):  
Li Juan Liu ◽  
Ming Lv ◽  
Wen Ge Wu
Keyword(s):  
Neural Networks ◽  
High Speed ◽  
Cutting Parameters ◽  
Database System ◽  
Machining Parameters ◽  
Relevant Research ◽  
Selection Scheme ◽  
High Speed Cutting ◽  
Parameters Selection ◽  
Choice Method

High speed cutting (HSM) is one of the main trends of cutting machinery. In our country, the relevant research of HSM starts later, the actual machining and experiment on the machining technology and the machining parameters of HSM are few, the reasonable machining parameters selection scheme and the appropriate cutter choice method are lack. The paper established the HSM cutters management system based on BP artificial neural networks to facilitate optimized database system and to improve cutting efficiency. The result shows the system is very helpful to select cutting parameters and the value of prediction fits with the test very well.

Optimization of Machining Parameters During Turning of Tungsten Heavy Alloys Using Taguchi Analysis

2019 ◽  
Author(s):  
Chithajalu Kiran Sagar ◽  
Amrita Priyadarshini ◽  
Amit Kumar Gupta
Keyword(s):  
Surface Roughness ◽  
Cutting Forces ◽  
Metal Removal ◽  
Cutting Parameters ◽  
Machining Parameters ◽  
Taguchi Analysis ◽  
Heavy Alloys ◽  
Wide Range ◽  
Tungsten Heavy Alloys ◽  
Machining Parameter

Abstract Tungsten heavy alloys (WHAs) are ideally suited to a wide range of density applications such as counterweights, inertial masses, radiation shielding, sporting goods and ordnance products. Manufacturing of these components essentially require machining to achieve desired finish, dimensions and tolerances However, machining of WHAs are extremely challenging because of higher values of elastic stiffness and hardness. Hence, there is a need to find the right combination of cutting parameters to carry out the machining operations efficiently. In the present work, turning tests are conducted on three different grades of WHAs, namely, 90WHA, 95WHA and 97WHA. Taguchi analysis is carried out to find out the most contributing factor as well as optimum cutting parameters that can give higher metal removal rate (MRR), lower surface roughness and lower cutting forces. It is observed that feed rate is the most prominent factor with percentage contribution varying in the range of 46–61%; whereas cutting speed has least effect on cutting forces, especially for 95WHA and 97WHA. Optimum values of forces, surface roughness and MRR and the corresponding machining parameters to be taken are presented. It is observed that 95W WHA has slightly better machinability as compared to other two grades since it gives highest MRR with lowest cutting forces and surface roughness values. The optimum machining parameter settings, so predicted, can be utilized to machine WHAs efficiently for manufacture of counter weights and inertial masses used in aerospace applications.

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