3-Dimensional kinematics simulation of face milling

Tapoglou, Nikolaos; Antoniadis, Aristomenis

doi:10.1016/j.measurement.2012.03.026

Cited by 25 publications

(6 citation statements)

References 32 publications

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“…A large amount of research has been undertaken in the area, resulting in efficient ways of simulating and predicting in cut characteristics. In the area of simulation of manufacturing processes, a series of approaches have been presented by researchers including analytical-, simulation-and experimentalbased models [6][7][8][9][10][11][12][13][14][15]. The most common simulation models include finite element and mathematical models.…”

Section: State Of the Artmentioning

confidence: 99%

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Development of Cutting Force Model and Process Maps for Power Skiving Using CAD-Based Modelling

Tapoglou

2021

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Power skiving is a new gear cutting process that has been recognized to provide a step change in the production rate achieved in the machining of high-precision internal and external involute gears. The process is based on a continuous generating meshing between the workgear and the cutting tool. Understanding of the loads applied in the cutting tool, and therefore some of the sources of tool wear, have not been thoroughly understood. This paper presents a novel model that is able to predict with high accuracy the cutting forces in the power skiving process. The model is based on a solid modelling simulation algorithm that produces high-fidelity solid bodies that are used for the calculations. The results of the model have been experimentally validated. A series of process maps are also produced to assist in the identification of the optimal machining parameters.

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Section: State Of the Artmentioning

confidence: 99%

“…Tapoglou and Antoniadis [9] investigated the equivalent macro-face-milling process using a CAD-based approach in order to predict the final surface quality and the cutting forces developed in the face-milling process.…”

Section: State Of the Artmentioning

confidence: 99%

Development of Cutting Force Model and Process Maps for Power Skiving Using CAD-Based Modelling

Tapoglou

2021

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“…In many other investigations, in which different simulation environments were used, the resulting kinematic roughness by the milling tool was also investigated. For example, Tapoglou and Antoniadis modeled the resulting roughness of the workpiece surface using the exact geometry of the cutting tool [16]. Their simulation was embedded in a commercial CAD environment.…”

Section: Contact Point Radius V Cmentioning

confidence: 99%

Analysis of dimensional accuracy for micro-milled areal material measures with kinematic simulation

Klauer

Eifler

Kirsch

et al. 2021

Int J Adv Manuf Technol

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The calibration of areal surface topography measuring instruments is of high relevance to estimate the measurement uncertainty and to guarantee the traceability of the measurement results. Calibration structures for optical measuring instruments must be sufficiently small to determine the limits of the instruments.Besides other methods, micro-milling is a suitable process for manufacturing areal material measures. For the manufacturing by micro-milling with ball end mills, the tool radius (effective cutter radius) is the corresponding limiting factor: if the tool radius is too large to penetrate the concave profile details without removing the surrounding material, deviations from the target geometry will occur. These deviations can be detected and excluded before experimental manufacturing with the aid of a kinematic simulation.In this study, a kinematic simulation model for the prediction of the dimensional accuracy of micro-milled areal material measures is developed and validated. Subsequently, a radius study is conducted to determine how the tool radius r of the tool influences the dimensional accuracy of an areal crossed sinusoidal (ACS) geometry according to ISO 25178-70 [1] with a defined amplitude d and period length p. The resulting theoretical surface texture parameters are evaluated and compared to the target values. It was shown that the surface texture parameters deviate from the nominal values depending on the effective cutter radius used. Based on the results of the study, it can be determined with which effective tool radius the measurands Sa and Sq of the material measures are best met. The ideal effective radius for the application considered is between 50 and 75 μm.

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“…The authors concluded that the best results were obtained for the radius of 15 µm, for which the lowest forces were recorded, as well as the lowest surface roughness and the longest tool lifetime. Tapoglou and Anoniadis [ 21 ] conducted the simulation tests based on the accurate CAD model of a cutting insert. Consecutive cutting edge positions were generated in order to reproduce the actual kinematics of face milling.…”

Section: Introductionmentioning

confidence: 99%

High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude

et al. 2021

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High feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the high feed milling (HFM), experimental tests were conducted, preceded by an analysis of cutting zones when milling with an HF face cutter. The face milling tests of 42CrMo4 steel with the use of an HF cutter characterized by an entering angle, dependent on axial depth of cut ap and insert radius r values, as well as with a conventional face cutter with the entering angle of 45° were performed. The study focused on analyzing the vibration amplitude, cutting force components in the workpiece coordinate system, and surface roughness. The experimental tests proved, that when milling with constant cut layer thickness, the high feed cutter allowed to obtain twice the cutting volume in comparison with the conventional face cutter. However, higher machining efficiency resulted in an increase in cutting force components. Furthermore, the results indicate significantly higher surface roughness and higher vibration amplitudes when milling with the HF cutter.

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3-Dimensional kinematics simulation of face milling

Cited by 25 publications

References 32 publications

Development of Cutting Force Model and Process Maps for Power Skiving Using CAD-Based Modelling

Development of Cutting Force Model and Process Maps for Power Skiving Using CAD-Based Modelling

Analysis of dimensional accuracy for micro-milled areal material measures with kinematic simulation

High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude

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