Recording of real cutting forces along the milling of complex parts

Lacalle, Luís Norberto López de; Lamíkiz, Aitzol; Sánchez, J.A.; Bustos, Igor Fernández de

doi:10.1016/j.mechatronics.2005.09.001

Cited by 60 publications

(29 citation statements)

References 19 publications

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“…The on-line recording of the current cutting edge position with respect to the specimen during the machining process is described in Reference [27]. Schütte discovered that the cutting force causes the rise of feed forces while drilling with pilot bore [28].…”

Section: Methodsmentioning

confidence: 99%

Process Forces Analysis and a New Feed Control Strategy for Drilling of Unidirectional Carbon Fiber Reinforced Plastics (UD-CFRP)

Sauer

Dix

Pütz

2018

JMMP

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Reliable machining of carbon fiber-reinforced plastics (CFRP) is the key for application of these lightweight materials. Due to its anisotropy, CFRP is a very difficult material to machine because of occurring delamination and fiber-pullouts. The tool design is especially crucial to minimize and to avoid these processing errors. In this paper a process analysis for drilling is shown for better understanding of the chip formation. Drilling of unidirectional CFRP enables the investigation of the effect of fiber orientation on the chip formation process. In theory, the amount of cut fibers and the cutting angle to the main cutting edge determine the cutting force. Experimental tests with varied macroscopic drill geometries verify this theory. Based on these detected relationships, the tool loads can be calculated for a successful tool design.

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Section: Methodsmentioning

confidence: 99%

Process Forces Analysis and a New Feed Control Strategy for Drilling of Unidirectional Carbon Fiber Reinforced Plastics (UD-CFRP)

Sauer

Dix

Pütz

2018

JMMP

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“…The minimum chip thickness were associated with the lower and constant cutting forces rather than the larger chip thickness values. Therefore, the unexpected cutting forces' high and variable values were avoided, and as a consequence, possible machining errors, such as material overcut or undercut (dimensional errors), were not present [27,28]. For the roughing process (Table 3), five different machining strategies were tested.…”

Section: Integrated Roughing-semifinishing-finishing Approachmentioning

confidence: 99%

Five-Axis Milling of Large Spiral Bevel Gears: Toolpath Definition, Finishing, and Shape Errors

Álvarez¹,

Calleja

Ortega

et al. 2018

Metals

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Abstract:In this paper, a five-axis machining process is analyzed for large spiral-bevel gears, an interesting process for one-of-kind manufacturing. The work is focused on large sized spiral bevel gears manufacturing using universal multitasking machines or five-axis milling centers. Different machining strategies, toolpath patterns, and parameters are tested for both gear roughing and finishing operations. Machining time, tools' wear, and gear surface are analyzed in order to determine which are the best strategies and parameters for large modulus gear manufacturing on universal machines. The case study results are discussed in the last section, showing the capacity of a universal five-axis milling for this niche. Special attention was paid to the possible affectations of the metal surfaces, since gear durability is very sensitive to thermo-mechanical damage, affected layers, and flank gear surface state.

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“…In the processes of curved surface milling of complex parts and thin-walled parts, the machining accuracy directly affects the production quality of the parts [1]. The machining accuracy of machine tools is affected by various factors such as the dimensional accuracy of machine components, motion accuracy, deformations, and distortions generated by cutting force and cutting heat [2][3][4].…”

Section: Introductionmentioning

confidence: 99%

Geometric Error Identification and Analysis of Rotary Axes on Five-Axis Machine Tool Based on Precision Balls

Liu

et al. 2019

Applied Sciences

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This paper presents the design of a precise "ball-column" device to efficiently and accurately measure the geometric error terms of both rotary axes of the five-axis machine tool. A geometric error measurement method of spherical contact was proposed based on the influence of the geometric error term from a five-axis machine tool rotating axis on the integrated geometric error of the machine tool. A multiple degree of freedom, step-by-step contact method based on on-machine measure for measuring the spherical center point is proposed, and the solution formula of each geometric error term of the rotating axis is established, respectively. This method can identify 12 geometric errors based on the influence of one rotating axis on another rotating axis after long term operation. The spatial error field of the five-axis machine tool was constructed by analyzing the error law of the two rotating axes of machine tools based on various positions and postures. Finally, after the comparison of the experiment, the results showed that the accuracy of the developed error measurement device reached 91.8% and the detection time was as short as 30-40 min.

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Recording of real cutting forces along the milling of complex parts

Cited by 60 publications

References 19 publications

Process Forces Analysis and a New Feed Control Strategy for Drilling of Unidirectional Carbon Fiber Reinforced Plastics (UD-CFRP)

Process Forces Analysis and a New Feed Control Strategy for Drilling of Unidirectional Carbon Fiber Reinforced Plastics (UD-CFRP)

Five-Axis Milling of Large Spiral Bevel Gears: Toolpath Definition, Finishing, and Shape Errors

Geometric Error Identification and Analysis of Rotary Axes on Five-Axis Machine Tool Based on Precision Balls

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