On a Methodology for Establishing the Machine Tool System Requirements for High-Speed/High-Throughput Machining

Abstract

This paper presents a methodology for determining the machine tool system requirements for high-speed machining (HSM)/high-throughput machining (HTM). Both technological and economic factors should be considered in the formulation of the model for determining machine tool system requirements. The HSM function model is given here in the form of ICAM-defined (IDEFo) charts with corresponding text. For machining most aluminum alloys, the maximum cutting speed is not limited by tool life, and the technology for high-speed machine tools (spindles, table drives, controls, chip management, and other features) exists today. Therefore, HSM of aluminum alloys can be implemented. Selection of a suitable HSM system involves detailed technological analysis and economic justification for a given part-family production configuration. The recent introduction of Si3N4 based tool materials has enabled significantly higher cutting speeds (up to 1524 mpm or 5000 sfpm) in the machining of gray cast iron. However, the machine tools using this type of tool material should be more rigid and capable of higher power, higher speed, and faster feed in order to increase productivity and reduce manufacturing costs. In the machining of the difficult-to-machine materials (e.g., superalloys), the cutting speed is still limited by tool wear. Nevertheless, a high-throughput machining (HTM) strategy is pertinent for this application.

Active integration of tool deflection effects in end milling. Part 1. Prediction of milled surfaces

“…In the literature different characterisations for this couple are proposed. Some are quite simple: Smith [10] and Komanduri [6] fix the value of K R to a given and constant value whatever the cutting conditions are. The applications described in this paper use the formulation proposed by Kline and Devor [5]: this model takes into account the evolution of the following cutting parameters: the cutting depth E R , the cutting height E A and the feed per tooth A D (Fig.…”

Tool trajectory generation based on tool deflection effects in flat-end milling process(I)

“…From this model, not only the cutting forces along any direction (distributed along the tool flute) but also the duri and McGee (Komanduri & McGee, 1984) used a definition of K T and K R as constants in order to describe the relationship between the coefficients and the cutting conditions. These approaches become applicable to the cutting process when the influences of the cutting conditions are not significant.…”

An application of Taguchi method on the high-speed motorized spindle system design

“…High-speed machining (HSM) is an emerging material removal processing technology. Although theories of high-speed metal cutting can be traced back to the 1930s, commercial machine tools capable of achieving these cutting speeds did not exist until the late 1980s [1,2]. Only recently, industries have started experimenting with the use of high-speed machine tools in production.…”