Comparison of Modeling Methods to Determine Cutting Tool Profile for Conventional and Synchronized Whirling

Zanger, Frederik; Sellmeier, Volker; Klose, Jan; Bartkowiak, Miriam; Schulze, Volker

doi:10.1016/j.procir.2017.03.216

Cited by 29 publications

(12 citation statements)

References 1 publication

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“…Investigation of the influence of the error of the tool setup on the accuracy of the profile by the numerical and analytical method. The definition of the profiles of a cutting tool for normal and synchronized rotations by numerical and analytical methods is analyzed (Zanger et al, 2017). Both models showed the same geometry of the cutting tool, except that the analytical model showed bifurcations that lead to a trimming in the processing of the part.…”

Section: Previous Analytical Author Researches About Influence Of Inamentioning

confidence: 99%

Analytical investigations of the accuracy of the small diameter tool-joint tapered thread made by a lathe machining

Onysko

Kopei

Medvid

et al. 2019

New Trends in Production Engineering

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The drill string consists of connected drill pipes and other elements. The connection is carried out by screwing of the drill string elements with the help of tool-joint tapered thread. The operational characteristics of the drill pipes depend of the manufacture precision of these tool-joints mostly. The accuracy of the thread is regulated by the accuracy of its profile and the accuracy of its pitch diameter value. The accuracy of the tapered thread manufacturing on the lathe in its depending on the values of the geometric parameters of the lathe tool and the values of deviations of its installation relatively to the workpiece axis is investigated. It is proved that for the tapered thread of form VI profile used for connection of drill pipes with the diameter from 30 mm to 44 mm the most influential factor, in relation to the accuracy of the thread profile is the value of the rake angle. Application of the rake angle value up to −5° according to the research data leads to a deviation from the specified profile of 0.3°, which is more than 35% of the declared standard tolerance on deviations from the profile. Also, the influence of the back rake angle value on the value of the deviation from the standard pitch diameter of the thread is proved. It is proved that the magnitude of the tangential displacement of the nose of the cutter relatively to the axis of the thread up to −0.2 mm can cause a deviation of the profile angle of 0.18°, which is 27% of the standard tolerance.

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Section: Previous Analytical Author Researches About Influence Of Inamentioning

confidence: 99%

Analytical investigations of the accuracy of the small diameter tool-joint tapered thread made by a lathe machining

Onysko

Kopei

Medvid

et al. 2019

New Trends in Production Engineering

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show abstract

“…1. It has numerous advantages, such as a high cutting rate of approximately nine times of traditional milling (Mohan and Shunmugam, 2007), high surface integrity of machined surfaces (Zanger et al, 2017) and low cost (Han and Liu, 2013). As opposed to the machining processes of typical turning or milling, the whirling milling process has a special material removal mechanism led from the combination of workpiece rotation, cutting tools rotation, cutting tools axial feed motion, the interrupted cut by multiple cutting tools, and time variant characteristics of un-deformed chips.…”

Section: Introductionmentioning

confidence: 99%

An analytical model for predicting specific cutting energy in whirling milling process

Wang

et al. 2019

Journal of Cleaner Production

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The specific cutting energy (SCE) of machining processes is a significant indicator for machining sustainability. However, the characteristics of SCE in whirling milling as a promising green process are unknown because of the special material removal mechanism of this process. This paper presents an analytical model for predicting SCE based on the material removal mechanism of whirling milling. The cutting parameters affecting the SCE characteristics are identified considering the un-deformed chip formation. An analytical model is developed as functions of the identified cutting parameters by calculating material removal volume and cutting forces. To validate the proposed model, the analytical model was applied in ball screw shaft whirling milling. The results indicate that the analytical model can be effectively used to predict the SCE with over 90% accuracy. In addition, the effects of cutting parameters and material removal rate (MRR) on SCE were investigated and analyzed based on the proposed model, which can provide valuable information and guidance for the optimal selection of cutting parameters to minimize SCE and improve MRR.

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“…The typical manufacturing process used for an internal thread is forming or cut tapping [6], but there are other two options: internal whirling and thread milling. Internal whirling depends on precision multi-axis machine, with a synchronized rotation of tool and workpiece [7]. In tapping, residual stresses could be much higher if compared to thread milling or whirling.…”

Section: Introductionmentioning

confidence: 99%

Investigation of tool deflection during milling of thread in Cr-Co dental implant

Araujo

Fromentin

2018

Int J Adv Manuf Technol

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Milling is a good option for manufacturing internal threads in hard-to-cut dental components due to lower cutting forces. In the case of a very small drilled diameter, the tool cannot be large enough to reduce tool deflection nor sufficiently small to avoid the influence of the tool penetration. As a consequence, both situations need to be considered and no other research study dealt with this aspect for the modeling of thread milling forces. This article deals with the analysis of forces, deflection, and undercutting during machining of one typical internal thread geometry used for implants in a chrome-cobalt dental alloy. The geometry is analyzed considering the influence of tool penetration and it is presented new equations to identify the regions where it occurs. Machining experiments are conducted acquiring cutting forces and tool axis position in order to calculate the tool radial forces and estimate tool deflection. Manufactured threads geometry is measured to evaluate dimension quality. It can be claimed that the tool trajectory should consider one extra revolution around the drilled hole in order to machine the undercut material due to tool deflection for this small tool diameter.

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Comparison of Modeling Methods to Determine Cutting Tool Profile for Conventional and Synchronized Whirling

Cited by 29 publications

References 1 publication

Analytical investigations of the accuracy of the small diameter tool-joint tapered thread made by a lathe machining

Analytical investigations of the accuracy of the small diameter tool-joint tapered thread made by a lathe machining

An analytical model for predicting specific cutting energy in whirling milling process

Investigation of tool deflection during milling of thread in Cr-Co dental implant

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