Computer aided process planning for high-speed milling of thin-walled parts

Popma, M.G.R.

doi:10.3990/1.9789036530408

Cited by 8 publications

(6 citation statements)

References 27 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In up milling, although in a brief moment at the beginning of the tool tooth action, the tool pushes the blade (when the plastic deformation of the volume of material occurs prior to chip shearing, i.e. before the entrance of the tooth into the material to promote the cutting), during most of the cutting process the tool pulls the piece [17]. This fact is responsible for the negative result of the form error (removal of material beyond the nominal size).…”

Section: Assessment Of Form Errorsmentioning

confidence: 99%

Evaluating the influences of the cutting parameters on the surface roughness and form errors in 4-axis milling of thin-walled free-form parts of AISI H13 steel

Oliveira

Souza

Diniz

2018

J Braz. Soc. Mech. Sci. Eng.

View full text Add to dashboard Cite

The machining of complex surfaces such as those present in rotors, impeller blades, thin-walled parts among other engineering components has been commonly carried out in multi-axis CNC machines programmed by CAD/CAM software. Even with a significant aid of the CAD/CAM systems, the users are responsible for defining an optimal set of cutting parameters, relying on their practical knowledge. This task gets harder when thin-walled parts have to be milled, because besides the problems caused by the limit of rigidity of the cutting tool, there is also the limit of rigidity of the thin-walled parts. Few works can be found on current literature concerning this issue. Then, the current work aims to analyse the influences of the cutting parameters: feed per tooth (f z); radial depth of cut (a e); and cutting direction (up and down milling), on the form errors and surface roughness of thin-walled parts manufactured by 4-axis milling using AISI H13 steel. The results show that the cutting direction (up/down milling) was the major variable to affect the form errors. Down milling left more than 0.2 mm of material on the machined part. On the opposite, up milling removes up to 0.2 mm more material than it should be. ANOVA shows that the influence of the f z on the form error is slightly higher than a e influence. In extreme cases, it can be about 1.5 times more influent than a e. Down milling and the highest values of a e and f z tested proved to be a good set of cutting conditions for milling free-form thin-walled parts, because with these conditions a good surface roughness, a positive form error and higher productivity were obtained.

show abstract

Section: Assessment Of Form Errorsmentioning

confidence: 99%

Evaluating the influences of the cutting parameters on the surface roughness and form errors in 4-axis milling of thin-walled free-form parts of AISI H13 steel

Oliveira

Souza

Diniz

2018

J Braz. Soc. Mech. Sci. Eng.

View full text Add to dashboard Cite

show abstract

“…This aluminum alloy has very good mechanical properties, high fatigue, and corrosion resistance, making it suitable for the machining of thin-walled structures. To avoid deformations in the machining process, analysis of the positive cases from the literature [9,28] and previous implementation of the experiments made it possible to choose a strategy of alternating machining of both sides of the wall. According to Figure 4, the case with the depth of cut of δ = 3 mm is represented.…”

Section: Realizing the Experimentsmentioning

confidence: 99%

“…However, concerning surface roughness and machining time, the parallel spiral strategy was more promising when compared to other strategies. Popma [28] developed a system for automated generative computer-aided process planning (CAPP) for thin-walled parts machined on high-speed CNC machines with a special emphasis on machining sequence and strategies for thin-walled parts while achieving accuracy and quality of machining.…”

mentioning

confidence: 99%

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

Lukić

Čep

Vukman

et al. 2020

Metals

View full text Add to dashboard Cite

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.

show abstract

“…The formation of surfaces of thin-walled parts with variable low stiffness requires a consideration of a number of factors that could prevent the achievement of technological requirements for the product [6,7]. Such factors are: deviations from a given shape that increases during processing, vibrations, thermal deformations and errors caused by tools, tool-path accuracy, technological equipment [8,9] and fixtures [10,11].…”

Section: Literature Reviewmentioning

confidence: 99%

Deflections and Frequency Analysis in the Milling of Thin-Walled Parts With Variable Low Stiffness

et al. 2019

View full text Add to dashboard Cite

The disadvantage of the geometry of thin-walled parts, in terms of processing, is the low ability to resist static and dynamic loads. It is caused by the elastic deformation of elements with a low stiffness. Modelling approaches for the evaluation of deflections during machining are presented. Mathematical models of deflections, cutting forces and harmonic response are proposed. The processes of material removal and deflection of a thin-walled sample at the critical points are modelled. A frequency analysis was performed, consisting of a modal analysis of natural frequencies and a harmonic response analysis. As a result, a graph of the deflections amplitude from the frequency of driven harmonic oscillations is generated. The analysis of the obtained values was performed. As a result, the resonance frequency and maximum amplitude of oscillations for the operating parameters are determined.

show abstract

Computer aided process planning for high-speed milling of thin-walled parts

Cited by 8 publications

References 27 publications

Evaluating the influences of the cutting parameters on the surface roughness and form errors in 4-axis milling of thin-walled free-form parts of AISI H13 steel

Evaluating the influences of the cutting parameters on the surface roughness and form errors in 4-axis milling of thin-walled free-form parts of AISI H13 steel

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

Deflections and Frequency Analysis in the Milling of Thin-Walled Parts With Variable Low Stiffness

Contact Info

Product

Resources

About