Deflection Error Prediction and Minimization in 5-Axis Milling Operations of Thin-Walled Impeller Blades

Soori, Mohsen; Asmael, Mohammed

doi:10.21203/rs.3.rs-87233/v1

Cited by 6 publications

(6 citation statements)

References 27 publications

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“…To reduce the deflection error in five-axis milling of impeller blades, Soori and Asmael 35 proposed an advanced virtual machining technique. A sophisticated virtual machining technique was established by Soori et al 28 in order to enhance surface quality during five-axis milling operations of turbine blades.…”

Section: Introductionmentioning

confidence: 99%

Cutting tool wear minimization in drilling operations of titanium alloy Ti-6Al-4V

Soori

Arezoo

2023

Proceedings of the Institution of Mechanical Engineers, Part J:

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Cutting tool wear during drilling operations can cause damage to cutting tools, machine tools, and workpieces which should be analyzed and minimized. Cutting tool wear impacts not just tool life but also the quality of the final product in terms of dimensional accuracy and surface integrity. High mechanical and thermal loads are generated during drilling operations of difficult-to-cut materials such as Ti-6Al-4V alloy which can reduce the life of cutting tool during chip formation process. Thus, to increase the accuracy of drilled parts from titanium alloy Ti6-Al-4V, the cutting tool wear during drilling operations should be accurately predicted in order to be minimized. Application of virtual machining systems is developed in the study in order to predict and minimize the cutting tool wear during drilling operations of titanium alloy Ti-6Al-4V. To predict the tool wear during drilling operations, cutting forces and temperature are calculated. Then, the finite element method (FEM) is utilized to predict the tool wear using the analytical model of Takeyama–Murata and updating the cutting tool geometry during chip formation process. To minimize the cutting tool wear during drilling operations, the optimum drilling parameters of feed rate and spindle speed are obtained using the Taguchi method-based response surface analysis algorithm. As a result, optimized drilling parameters are used in order to minimize the cutting tool wear during drilling operations. To validate the study, the experimental works are implemented to the sample workpiece from titanium alloy Ti6-Al4-V and the values of tool wear are then measured. To present the effectiveness of the proposed virtual machining system in minimization of cutting tool wear, the obtained results with and without optimized machining parameters are evaluated and compared. So, precision and productivity in drilling operations of titanium alloy Ti6-Al4-V can be enhanced using the developed virtual machining system in the study.

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Section: Introductionmentioning

confidence: 99%

Cutting tool wear minimization in drilling operations of titanium alloy Ti-6Al-4V

Soori

Arezoo

2023

Proceedings of the Institution of Mechanical Engineers, Part J:

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“…As presented in the studies of Soori and Asmael [11] and in Figure 1, the dimensional error of the milled surface is the sum of deformations caused by the components of the cutting force and thermal deformations. Where δ t,p and δ f,p are the normal projections of the cutting force and the deflection error induced by the cutting temperature for point P, respectively.…”

Section: Introductionmentioning

confidence: 95%

“…1. Manufacturing error caused by deformations from the milling process and thermal deformations [11] show the effectiveness in models used to predict post-machining deformations, which saves time and money, which are so important in industries where such shapes of elements occur.…”

Section: Introductionmentioning

confidence: 99%

Classification of Deflections of Thin-Walled Elements Made of EN AW-7075A Aluminum Alloy During Milling

Czyżycki,

Marciniak-Podsadna,

Twardowski

2023

Adv. Sci. Technol. Res. J.

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The aim of the research is to classify and evaluate the size of deformations appearing during milling of thin-walled elements representing a pocket form made of aluminum alloy EN AW-7075A. Finishing, which is the purpose of the research, was carried out at the full depth of cut a p = 15 mm, milling the entire height of the wall in one pass. Deformations during machining were correlated with the geometric accuracy of the workpieces after machining. During the tests, deformations were measured with a laser displacement sensor, and the temperature of the samples was measured using a resistance temperature sensor. The tests made it possible to identify deformations occurring during the milling of thin-walled elements. The course of deformation during milling was analyzed, from which the value of deformation caused by milling, the reaction to this deformation and its time were extracted, additionally, permanent distortion of the workpiece was detected. The results show the effect of the ratio of the height to the thickness of the thin-walled element on its geometric accuracy after machining in the form of straightness and flatness of the samples. The test results were compared to the tests carried out on the Ti6Al4V titanium alloy, which confirmed the influence of the material selection on the course of deformations during milling.

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“…Other studies, in turn, lead to the correction of the tool path and the selection of optimal technological parameters in order to minimize the deformation of the processed materialand the possibility of chatter [ 7 , 8 , 9 , 10 ].…”

Section: Introductionmentioning

confidence: 99%

“…The research [ 7 ] made it possible to reduce the flatness deviation of the milled element by 45% by obtaining an optimized tool path by predicting the deflection of a thin-walled workpiece using the finite element method. Similarly, Soori and Asmael [ 10 ] presented the results of the tool path optimization based on the developed algorithm based on the finite element method and the analytical model. Compensation allowed them to reduce deformations by half.…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Displacement of Thin-Walled Workpiece Using a High-Speed Camera during Peripheral Milling of Aluminum Alloys

2021

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The paper presents the possibilities of a high-speed camera in recording displacements of thin-walled workpiece during milling made of aluminum alloys, which allowed for an analysis in which it was compared to other methods of testing the deflection of such elements. The tests were carried out during peripheral milling with constant cutting parameters. Deflection of thin-walled workpiece due to cutting forces was measured using a high-speed camera and a laser displacement sensor. Additionally, the experimental results were compared with the theoretical results obtained with the use of the finite element method. The research proved the effectiveness of the use of high-speed camera in diagnostics of thin-walled workpieces during milling with an accuracy of up to 11% compared to measurements made with a displacement laser sensor.

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Deflection Error Prediction and Minimization in 5-Axis Milling Operations of Thin-Walled Impeller Blades

Cited by 6 publications

References 27 publications

Cutting tool wear minimization in drilling operations of titanium alloy Ti-6Al-4V

Cutting tool wear minimization in drilling operations of titanium alloy Ti-6Al-4V

Classification of Deflections of Thin-Walled Elements Made of EN AW-7075A Aluminum Alloy During Milling

Analysis of the Displacement of Thin-Walled Workpiece Using a High-Speed Camera during Peripheral Milling of Aluminum Alloys

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