Simulation of whirling process and tool profiling for machining of worms

Mohan, L.; Shunmugam, M.S.

doi:10.1016/j.jmatprotec.2006.03.115

Cited by 44 publications

(10 citation statements)

References 9 publications

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“…Studies have been conducted to simulate the whirling milling process. Mohan and Shunmugam (2007) simulated the tool profile of whirling milling for worm screws based on homogeneous coordinate transformation of discrete surface coordinates. However, because the simulation model used discrete surface coordinates, it is not suitable for investigating the un-deformed chip formation which has a significant effect on SCE and cutting forces.…”

Section: Cutting Force Modelmentioning

confidence: 99%

“…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%

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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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Section: Cutting Force Modelmentioning

confidence: 99%

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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“…In the whirlwind milling process, the generated surface was simulated due to the contact nature between tool and workpiece, and the tool was profiled to avoid interference with workpiece (Mohan and Shunmugam, 2007). Aiming at modeling the whirlwind milling, profiling of tool was designed separately based on the normal section of screw trajectory and tool-workpiece contact conditions, which improve the forming precision and surface roughness (Ni et al, 2012).…”

Section: Introductionmentioning

confidence: 99%

Comparative Assessment of Surface Roughness and Microstructure Produced in Whirlwind Milling of Bearing Steel

Guo

Wang

et al. 2014

Machining Science and Technology

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2 The surface roughness and deformation microstructure of the GCr15 subjected to whirlwind milling (WM) were characterized. The machined surface roughness was modeled for predicting, and effects of cutting parameters on surface roughness were studied. Microstructure evolution was investigated using electron backscatter diffraction (EBSD).The microstructure in the top surface evolved into sub-boundaries and highly misoriented grain boundaries, and consisted of a mixture of elongated subgrains. The average size was 167 × 10 2 nm 2 in WM zone, which was less than 194 × 10 2 nm 2 in the non-WM zone. The presence of slip lines within the deformed grains was clearly noticeable. The predicted average surface roughness was evidently smaller than the experimental result, but the same conclusion was determined in in the effects of cutting depths and cutting speeds on surface roughness. The variation tendencies of hardness profiles were initially proved to be almost consistent to that of user-defined boundaries average misorientation (Bs AM ) calculated from the data detected by EBSD. The proposed models were validated by comparing the predicted results with experimental data.

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“…By the whirling process, in which a series of profiled cutters remove material by passing over the workpiece at high cutting speeds, helical surfaces can be machined comparatively easily and fast. 11 However, the result of this kind of operation is dictated by the profile of the cutters. Due to the tooling difficulties and cost, the application of this method is inevitably limited to large batch production.…”

Section: Introductionmentioning

confidence: 99%

Theoretical modeling and error analysis for CNC whirling of the helical surfaces of custom screws using common inserts

Han

Liu

2013

Proceedings of the Institution of Mechanical Engineers, Part C:

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With the wide use of complex helical surfaces in screw components, it becomes more and more urgent to investigate efficient ways for the design and manufacture of components of this kind. This study establishes the mathematical model of helical surface based on discrete points on its axial section profile using cubic spline curve fitting method, and presents a theoretical approach to calculate the tool path for the whirling process which aims to produce the helical surface through enwrapping movements of standard cutters inserted in the tool ring. The approach is implemented in MATLAB environment focusing on the calculation of the cutter location points. After that, the theoretical machining error is analyzed focusing on the scallop height, which can be divided into axial and cross-sectional errors. Finally, a case study is provided, together with numerical simulation demonstrating the validity of the proposed approach.

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Simulation of whirling process and tool profiling for machining of worms

Cited by 44 publications

References 9 publications

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

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

Comparative Assessment of Surface Roughness and Microstructure Produced in Whirlwind Milling of Bearing Steel

Theoretical modeling and error analysis for CNC whirling of the helical surfaces of custom screws using common inserts

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