An analytical model taking feed rate effect into consideration for scallop height calculation in milling with torus-end cutter

Segonds, Stéphane; Seitier, Philippe; Bordreuil, Cyril; Bugarin, Florian; Rubio, Walter; Redonnet, Jean-Max

doi:10.1007/s10845-017-1360-0

Cited by 14 publications

(7 citation statements)

References 25 publications

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“…Hendriko [11] developed a model to calculate the scallop height of a toroidal cutter in 5-axis milling. His research shed new light on the problem of roughness in 5-axis milling, but also showed no correlation between kinematic and geometric parameters, which was similar in the work of Segonds et al [12].…”

Section: Introductionsupporting

confidence: 62%

Empirical Models for Surface Roughness and Topography in 5-Axis Milling Based on Analysis of Lead Angle and Curvature Radius of Sculptured Surfaces

Gdula

2020

Metals

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The orientation of the tool axis and the variable curvature of the machined profile of a sculptured surface have a significant impact on the roughness and topography of the surface in the process of 5-axis milling by means of a toroidal milling cutter. The selection of the orientation of the toroidal milling cutter axis relative to the radius of curvature of the machined surface profile is very important as it can provide a better surface quality and an even distribution of roughness parameters. In this paper, an attempt to carry out model tests to obtain mathematical relationships was made. These relationships were to determine the impact of the tool axis orientation and the variable curvature radius of the machined profile on the surface roughness and its topography in the 5-axis milling process of sculptured surfaces. The tests were conducted on an example of a turbine blade made of Inconel 718 alloy. A measurable effect of the work undertaken was the development of model relationships that can be applied in specialized modules of CAM (Computer Aided Manufacturing) systems supporting the programming of 5-axis machining of sculptured surfaces. The models developed will also make it possible to obtain an evenly distributed roughness on the machined sculptured surface, especially on the surface of the turbine blades of the Inconel 718 alloy, as indicated by the results of the tests carried out.

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Section: Introductionsupporting

confidence: 62%

Empirical Models for Surface Roughness and Topography in 5-Axis Milling Based on Analysis of Lead Angle and Curvature Radius of Sculptured Surfaces

Gdula

2020

Metals

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“…The optimal recommended values for tool path parameters were 6.68 mm for step over; 3.379 degrees for lead angle; 0.027 degrees for tilt angle and 6.338x10 -3 mm for maximum discretization step. Cut tolerance was set equal to 0.01mm as proposed for finishing molds and dies (Segonds et al 2017). Machining time was approximately 1min, 24sec.…”

Section: Methodology Validationmentioning

confidence: 99%

“…With the help of the aforementioned computations, consecutive chord errors e C (mm) are calculated by employing Equation 3. a is the stepover distance between passes, in mm. Although the relation among effective radii and scallop heights has been successfully realized (Redonnet et al 2013;Segonds et al 2017) no research has been conducted to experimentally verify it and finally deploy it as an essential attribute in taking part to the formulation of crucial objectives for testing optimization potentials in sculptured surface machining.…”

Section: Chord Error and Scallop Height Estimationmentioning

confidence: 99%

Globally optimal tool paths for sculptured surfaces with emphasis to machining error and cutting posture smoothness

Fountas

Vaxevanidis

Stergiou

et al. 2018

International Journal of Production Research

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Global optimization for manufacturing problems is mandatory for obtaining versatile benefits to facilitate modern industry. This paper deals with an original approach of globally optimizing tool paths to CNC-machine sculptured surfaces. The approach entails the development of a fully automated manufacturing software interface integrated by a non-conventional genetic/evolutionary algorithm to enable intelligent machining. These attributes have been built using already existing practical machining modelling tools such as CAM systems so as to deliver a truly viable computeraided manufacturing solution. Since global optimization is heavily based in the formulation of the problem, emphasis has been given to the definition of optimization criteria as crucial elements for representing performance. The criteria involve the machining error as a combined effect of chord error and scallop height, the tool path smoothness and productivity. Experiments have been designed considering several benchmark sculptured surfaces as well as tool path parameters to validate the aforementioned criteria. The new approach was implemented to another sculptured surface which has been extensively tested by previous research works. Results were compared to those available in the literature and it was found that the proposed approach can indeed constitute a promising and trustworthy technique for the global optimization of sculptured surface CNC tool paths.

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“…In addition, grabbing the geometrical relationships was extremely difficult with the twodimensional expression for the cutting edge geometry. Segonds et al [29] reported comparative results between theoretical and experimental studies in filleted end milling, while the results were inexplicably limited to a certain small range of step over distance. In three-dimensional (3D) expression, it was reported that mathematical complexities arose according to intersection problems of 3D geometries [30].…”

Section: Introductionmentioning

confidence: 99%

Remarkable Characteristics of a Novel Path Interval Determination in Filleted End Milling

Sekine¹,

Kameya²

2021

JESA

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This study describes remarkable characteristics of a novel path interval determination in filleted end milling with a tool inclination. CNC milling machine is one of the core technologies in practical manufacturing. Computer-aided technologies have contributed to the technological advancement. Tool path generation in computer-aided manufacturing is really important for CNC milling process. Although there are a lot of parameters treated in tool path generation, path interval is one of the influential factors in considering the balance between manufacturing efficiency and machined surface feature. A path interval determination in filleted end milling commonly entails the intersection problems with mathematical complexities in essence. The related studies have been reported so far, while there has scarcely been a procedure to cope effectively with the complexities. Hence, this study focused on a novel path interval determination proposed in our previous study. After the analytical discussions were made with the computational and experimental results, it was acquired from the explicit evidences that the novel procedure possessed remarkable characteristics contributable for a path interval determination in multi-axis filleted end milling.

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An analytical model taking feed rate effect into consideration for scallop height calculation in milling with torus-end cutter

Cited by 14 publications

References 25 publications

Empirical Models for Surface Roughness and Topography in 5-Axis Milling Based on Analysis of Lead Angle and Curvature Radius of Sculptured Surfaces

Empirical Models for Surface Roughness and Topography in 5-Axis Milling Based on Analysis of Lead Angle and Curvature Radius of Sculptured Surfaces

Globally optimal tool paths for sculptured surfaces with emphasis to machining error and cutting posture smoothness

Remarkable Characteristics of a Novel Path Interval Determination in Filleted End Milling

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