Search results for: high speed milling
6586 The Effect of High-speed Milling on Surface Roughness of Hardened Tool Steel
Authors: Manop Vorasri, Komson Jirapattarasilp, Sittichai Kaewkuekool
Abstract:The objective of this research was to study factors, which were affected on surface roughness in high speed milling of hardened tool steel. Material used in the experiment was tool steel JIS SKD 61 that hardened on 60 ±2 HRC. Full factorial experimental design was conducted on 3 factors and 3 levels (3 3 designs) with 2 replications. Factors were consisted of cutting speed, feed rate, and depth of cut. The results showed that influenced factor affected to surface roughness was cutting speed, feed rate and depth of cut which showed statistical significant. Higher cutting speed would cause on better surface quality. On the other hand, higher feed rate would cause on poorer surface quality. Interaction of factor was found that cutting speed and depth of cut were significantly to surface quality. The interaction of high cutting speed associated with low depth of cut affected to better surface quality than low cutting speed and high depth of cut.
Keywords: High-speed milling, Tool steel, SKD 61 Steel, Surface roughness, Cutting speed, Feed rate, Depth of cutProcedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1771
6585 Generating High-Accuracy Tool Path for 5-axis Flank Milling of Globoidal Spatial Cam
Authors: Li Chen, ZhouLong Li, Qing-zhen Bi, LiMin Zhu
Abstract:A new tool path planning method for 5-axis flank milling of a globoidal indexing cam is developed in this paper. The globoidal indexing cam is a practical transmission mechanism due to its high transmission speed, accuracy and dynamic performance. Machining the cam profile is a complex and precise task. The profile surface of the globoidal cam is generated by the conjugate contact motion of the roller. The generated complex profile surface is usually machined by 5-axis point-milling method. The point-milling method is time-consuming compared with flank milling. The tool path for 5-axis flank milling of globoidal cam is developed to improve the cutting efficiency. The flank milling tool path is globally optimized according to the minimum zone criterion, and high accuracy is guaranteed. The computational example and cutting simulation finally validate the developed method.
Keywords: Globoidal cam, flank milling, LSQR, MINIMAX.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2145
6584 Prediction of Temperature Distribution during Drilling Process Using Artificial Neural Network
Authors: Ali Reza Tahavvor, Saeed Hosseini, Nazli Jowkar, Afshin Karimzadeh Fard
Experimental & numeral study of temperature distribution during milling process, is important in milling quality and tools life aspects. In the present study the milling cross-section temperature is determined by using Artificial Neural Networks (ANN) according to the temperature of certain points of the work piece and the point specifications and the milling rotational speed of the blade. In the present work, at first three-dimensional model of the work piece is provided and then by using the Computational Heat Transfer (CHT) simulations, temperature in different nods of the work piece are specified in steady-state conditions. Results obtained from CHT are used for training and testing the ANN approach. Using reverse engineering and setting the desired x, y, z and the milling rotational speed of the blade as input data to the network, the milling surface temperature determined by neural network is presented as output data. The desired points temperature for different milling blade rotational speed are obtained experimentally and by extrapolation method for the milling surface temperature is obtained and a comparison is performed among the soft programming ANN, CHT results and experimental data and it is observed that ANN soft programming code can be used more efficiently to determine the temperature in a milling process.
Keywords: Milling process, rotational speed, Artificial Neural Networks, temperature.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2207
6583 The Effect of Tool Path Strategy on Surface and Dimension in High Speed Milling
Authors: A. Razavykia, A. Esmaeilzadeh, S. Iranmanesh
Abstract:Many orthopedic implants like proximal humerus cases require lower surface roughness and almost immediate/short lead time surgery. Thus, rapid response from the manufacturer is very crucial. Tool path strategy of milling process has a direct influence on the surface roughness and lead time of medical implant. High-speed milling as promised process would improve the machined surface quality, but conventional or super-abrasive grinding still required which imposes some drawbacks such as additional costs and time. Currently, many CAD/CAM software offers some different tool path strategies to milling free form surfaces. Nevertheless, the users must identify how to choose the strategies according to cutting tool geometry, geometry complexity, and their effects on the machined surface. This study investigates the effect of different tool path strategies for milling a proximal humerus head during finishing operation on stainless steel 316L. Experiments have been performed using MAHO MH700 S vertical milling machine and four machining strategies, namely, spiral outward, spiral inward, and radial as well as zig-zag. In all cases, the obtained surfaces were analyzed in terms of roughness and dimension accuracy compared with those obtained by simulation. The findings provide evidence that surface roughness, dimensional accuracy, and machining time have been affected by the considered tool path strategy.
Keywords: CAD/CAM software, milling, orthopedic implants, tool path strategy.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 847
6582 Prediction of the Dynamic Characteristics of a Milling Machine Using the Integrated Model of Machine Frame and Spindle Unit
Authors: Jui P. Hung, Yuan L. Lai, Tzuo L. Luo, Hsi H. Hsiao
Abstract:The machining performance is determined by the frequency characteristics of the machine-tool structure and the dynamics of the cutting process. Therefore, the prediction of dynamic vibration behavior of spindle tool system is of great importance for the design of a machine tool capable of high-precision and high-speed machining. The aim of this study is to develop a finite element model to predict the dynamic characteristics of milling machine tool and hence evaluate the influence of the preload of the spindle bearings. To this purpose, a three dimensional spindle bearing model of a high speed engraving spindle tool was created. In this model, the rolling interfaces with contact stiffness defined by Harris model were used to simulate the spindle bearing components. Then a full finite element model of a vertical milling machine was established by coupling the spindle tool unit with the machine frame structure. Using this model, the vibration mode that had a dominant influence on the dynamic stiffness was determined. The results of the finite element simulations reveal that spindle bearing with different preloads greatly affect the dynamic behavior of the spindle tool unit and hence the dynamic responses of the vertical column milling system. These results were validated by performing vibration on the individual spindle tool unit and the milling machine prototype, respectively. We conclude that preload of the spindle bearings is an important component affecting the dynamic characteristics and machining performance of the entire vertical column structure of the milling machine.
Keywords: Dynamic compliance, Milling machine, Spindle unit, Bearing preload.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3526
6581 Milling Chatter Prevention by Adaptive Spindle Speed Tuning
Authors: Nan-Chyuan Tsai, Din-Chang Chen, Rong-Mao Lee, Bai-Lu Wang
Abstract:This paper presents how the real-time chatter prevention can be realized by feedback of acoustic cutting signal, and the efficacy of the proposed adaptive spindle speed tuning algorithm is verified by intensive experimental simulations. A pair of microphones, perpendicular to each other, is used to acquire the acoustic cutting signal resulting from milling chatter. A real-time feedback control loop is constructed for spindle speed compensation so that the milling process can be ensured to be within the stability zone of stability lobe diagram. Acoustic Chatter Signal Index (ACSI) and Spindle Speed Compensation Strategy (SSCS) are proposed to quantify the acoustic signal and actively tune the spindle speed respectively. By converting the acoustic feedback signal into ACSI, an appropriate Spindle Speed Compensation Rate (SSCR) can be determined by SSCS based on real-time chatter level or ACSI. Accordingly, the compensation command, referred to as Added-On Voltage (AOV), is applied to increase/decrease the spindle motor speed. By inspection on the precision and quality of the workpiece surface after milling, the efficacy of the real-time chatter prevention strategy via acoustic signal feedback is further assured.
Keywords: Chatter compensation, Stability lobes, Non-invasivemeasurement.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1592
6580 Optimization of Surface Finish in Milling Operation Using Live Tooling via Taguchi Method
Authors: Harish Kumar Ponnappan, Joseph C. Chen
The main objective of this research is to optimize the surface roughness of a milling operation on AISI 1018 steel using live tooling on a HAAS ST-20 lathe. In this study, Taguchi analysis is used to optimize the milling process by investigating the effect of different machining parameters on surface roughness. The L9 orthogonal array is designed with four controllable factors with three different levels each and an uncontrollable factor, resulting in 18 experimental runs. The optimal parameters determined from Taguchi analysis were feed rate – 76.2 mm/min, spindle speed 1150 rpm, depth of cut – 0.762 mm and 2-flute TiN coated high-speed steel as tool material. The process capability Cp and process capability index Cpk values were improved from 0.62 and -0.44 to 1.39 and 1.24 respectively. The average surface roughness values from the confirmation runs were 1.30 µ, decreasing the defect rate from 87.72% to 0.01%. The purpose of this study is to efficiently utilize the Taguchi design to optimize the surface roughness in a milling operation using live tooling.
Keywords: Live tooling, surface roughness, Taguchi analysis, Computer Numerical Control (CNC) milling operation, CNC turning operation.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 576
6579 Neural Network Monitoring Strategy of Cutting Tool Wear of Horizontal High Speed Milling
Authors: Kious Mecheri, Hadjadj Abdechafik, Ameur Aissa
The wear of cutting tool degrades the quality of the product in the manufacturing processes. The on line monitoring of the cutting tool wear level is very necessary to prevent the deterioration of the quality of machining. Unfortunately there is not a direct manner to measure the cutting tool wear on line. Consequently we must adopt an indirect method where wear will be estimated from the measurement of one or more physical parameters appearing during the machining process such as the cutting force, the vibrations, or the acoustic emission etc…. In this work, a neural network system is elaborated in order to estimate the flank wear from the cutting force measurement and the cutting conditions.
Keywords: Flank wear, cutting forces, high speed milling, signal processing, neural network.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2446
6578 Chatter Stability Characterization of Full-Immersion End-Milling Using a Generalized Modified Map of the Full-Discretization Method, Part 1: Validation of Results and Study of Stability Lobes by Numerical Simulation
Authors: Chigbogu G. Ozoegwu, Sam N. Omenyi
The objective in this work is to generate and discuss the stability results of fully-immersed end-milling process with parameters; tool mass m=0.0431kg,tool natural frequency ωn = 5700 rads^-1, damping factor ξ=0.002 and workpiece cutting coefficient C=3.5x10^7 Nm^-7/4. Different no of teeth is considered for the end-milling. Both 1-DOF and 2-DOF chatter models of the system are generated on the basis of non-linear force law. Chatter stability analysis is carried out using a modified form (generalized for both 1-DOF and 2-DOF models) of recently developed method called Full-discretization. The full-immersion three tooth end-milling together with higher toothed end-milling processes has secondary Hopf bifurcation lobes (SHBL’s) that exhibit one turning (minimum) point each. Each of such SHBL is demarcated by its minimum point into two portions; (i) the Lower Spindle Speed Portion (LSSP) in which bifurcations occur in the right half portion of the unit circle centred at the origin of the complex plane and (ii) the Higher Spindle Speed Portion (HSSP) in which bifurcations occur in the left half portion of the unit circle. Comments are made regarding why bifurcation lobes should generally get bigger and more visible with increase in spindle speed and why flip bifurcation lobes (FBL’s) could be invisible in the low-speed stability chart but visible in the high-speed stability chart of the fully-immersed three-tooth miller.
Keywords: Chatter, flip bifurcation, modified full-discretization map stability lobe, secondary Hopf bifurcation.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1736
6577 Determining the Width and Depths of Cut in Milling on the Basis of a Multi-Dexel Model
Authors: Jens Friedrich, Matthias A. Gebele, Armin Lechler, Alexander Verl
Abstract:Chatter vibrations and process instabilities are the most important factors limiting the productivity of the milling process. Chatter can leads to damage of the tool, the part or the machine tool. Therefore, the estimation and prediction of the process stability is very important. The process stability depends on the spindle speed, the depth of cut and the width of cut. In milling, the process conditions are defined in the NC-program. While the spindle speed is directly coded in the NC-program, the depth and width of cut are unknown. This paper presents a new simulation based approach for the prediction of the depth and width of cut of a milling process. The prediction is based on a material removal simulation with an analytically represented tool shape and a multi-dexel approach for the workpiece. The new calculation method allows the direct estimation of the depth and width of cut, which are the influencing parameters of the process stability, instead of the removed volume as existing approaches do. The knowledge can be used to predict the stability of new, unknown parts. Moreover with an additional vibration sensor, the stability lobe diagram of a milling process can be estimated and improved based on the estimated depth and width of cut.
Keywords: Dexel, process stability, material removal, milling.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2118
6576 Effect of High-Energy Ball Milling on the Electrical and Piezoelectric Properties of (K0.5Na0.5)(Nb0.9Ta0.1)O3 Lead-Free Piezoceramics
Authors: Chongtham Jiten, K. Chandramani Singh, Radhapiyari Laishram
Nanocrystalline powders of the lead-free piezoelectric material, tantalum-substituted potassium sodium niobate (K0.5Na0.5)(Nb0.9Ta0.1)O3 (KNNT), were produced using a Retsch PM100 planetary ball mill by setting the milling time to 15h, 20h, 25h, 30h, 35h and 40h, at a fixed speed of 250rpm. The average particle size of the milled powders was found to decrease from 12nm to 3nm as the milling time increases from 15h to 25h, which is in agreement with the existing theoretical model. An anomalous increase to 98nm and then a drop to 3nm in the particle size were observed as the milling time further increases to 30h and 40h respectively. Various sizes of these starting KNNT powders were used to investigate the effect of milling time on the microstructure, dielectric properties, phase transitions and piezoelectric properties of the resulting KNNT ceramics. The particle size of starting KNNT was somewhat proportional to the grain size. As the milling time increases from 15h to 25h, the resulting ceramics exhibit enhancement in the values of relative density from 94.8% to 95.8%, room temperature dielectric constant (εRT) from 878 to 1213, and piezoelectric charge coefficient (d33) from 108pC/N to 128pC/N. For this range of ceramic samples, grain size refinement suppresses the maximum dielectric constant (εmax), shifts the Curie temperature (Tc) to a lower temperature and the orthorhombic-tetragonal phase transition (Tot) to a higher temperature. Further increase of milling time from 25h to 40h produces a gradual degradation in the values of relative density, εRT, and d33 of the resulting ceramics.
Keywords: Ceramics, Dielectric, High-energy milling, Perovskite.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2409
6575 Tool Wear of Metal Matrix Composite 10wt% AlN Reinforcement Using TiB2 Cutting Tool
Authors: M. S. Said, J. A. Ghani, Che Hassan C. H., N. N. Wan, M. A. Selamat, R. Othman
Metal matrix composites (MMCs) attract considerable attention as a result from its ability in providing a high strength, high modulus, high toughness, high impact properties, improving wear resistance and providing good corrosion resistance compared to unreinforced alloy. Aluminium Silicon (Al/Si) alloy MMC has been widely used in various industrial sectors such as in transportation, domestic equipment, aerospace, military, construction, etc. Aluminium silicon alloy is an MMC that had been reinforced with aluminium nitrate (AlN) particle and become a new generation material use in automotive and aerospace sector. The AlN is one of the advance material that have a bright prospect in future since it has features such as lightweight, high strength, high hardness and stiffness quality. However, the high degree of ceramic particle reinforcement and the irregular nature of the particles along the matrix material that contribute to its low density is the main problem which leads to difficulties in machining process. This paper examined the tool wear when milling AlSi/AlN Metal Matrix Composite using a TiB2 (Titanium diboride) coated carbide cutting tool. The volume of the AlN reinforced particle was 10% and milling process was carried out under dry cutting condition. The TiB2 coated carbide insert parameters used were at the cutting speed of (230, 300 and 370m/min, feed rate of 0.8, Depth of Cut (DoC) at 0.4m). The Sometech SV-35 video microscope system used to quantify of the tool wear. The result shown that tool life span increasing with the cutting speeds at (370m/min, feed rate of 0.8mm/tooth and DoC at 0.4mm) which constituted an optimum condition for longer tool life lasted until 123.2 mins. Meanwhile, at medium cutting speed which at 300m/m, feed rate of 0.8mm/tooth and depth of cut at 0.4mm we found that tool life span lasted until 119.86 mins while at low cutting speed it lasted in 119.66 mins. High cutting speed will give the best parameter in cutting AlSi/AlN MMCs material. The result will help manufacturers in machining process of AlSi/AlN MMCs materials.
Keywords: AlSi/AlN Metal Matrix Composite milling process, tool wear, TiB2 coated cemented carbide tool.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3053
6574 Finite Element Prediction on the Machining Stability of Milling Machine with Experimental Verification
Authors: Jui P. Hung, Yuan L. Lai, Hui T. You
Abstract:Chatter vibration has been a troublesome problem for a machine tool toward the high precision and high speed machining. Essentially, the machining performance is determined by the dynamic characteristics of the machine tool structure and dynamics of cutting process, which can further be identified in terms of the stability lobe diagram. Therefore, realization on the machine tool dynamic behavior can help to enhance the cutting stability. To assess the dynamic characteristics and machining stability of a vertical milling system under the influence of a linear guide, this study developed a finite element model integrated the modeling of linear components with the implementation of contact stiffness at the rolling interface. Both the finite element simulations and experimental measurements reveal that the linear guide with different preload greatly affects the vibration behavior and milling stability of the vertical column spindle head system, which also clearly indicate that the predictions of the machining stability agree well with the cutting tests. It is believed that the proposed model can be successfully applied to evaluate the dynamics performance of machine tool systems of various configurations.
Keywords: Machining stability, Vertical milling machine, Linearguide, Contact stiffness.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2459
6573 A Fuzzy Logic Based Model to Predict Surface Roughness of A Machined Surface in Glass Milling Operation Using CBN Grinding Tool
Authors: Ahmed A. D. Sarhan, M. Sayuti, M. Hamdi
Abstract:Nowadays, the demand for high product quality focuses extensive attention to the quality of machined surface. The (CNC) milling machine facilities provides a wide variety of parameters set-up, making the machining process on the glass excellent in manufacturing complicated special products compared to other machining processes. However, the application of grinding process on the CNC milling machine could be an ideal solution to improve the product quality, but adopting the right machining parameters is required. In glass milling operation, several machining parameters are considered to be significant in affecting surface roughness. These parameters include the lubrication pressure, spindle speed, feed rate and depth of cut. In this research work, a fuzzy logic model is offered to predict the surface roughness of a machined surface in glass milling operation using CBN grinding tool. Four membership functions are allocated to be connected with each input of the model. The predicted results achieved via fuzzy logic model are compared to the experimental result. The result demonstrated settlement between the fuzzy model and experimental results with the 93.103% accuracy.
Keywords: CNC-machine, Glass milling, Grinding, Surface roughness, Cutting force, Fuzzy logic model.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2535
6572 Analysis of Residual Strain and Stress Distributions in High Speed Milled Specimens using an Indentation Method
Authors: Felipe V. Díaz, Claudio A. Mammana, Armando P. M. Guidobono, Raúl E. Bolmaro
Abstract:Through a proper analysis of residual strain and stress distributions obtained at the surface of high speed milled specimens of AA 6082–T6 aluminium alloy, the performance of an improved indentation method is evaluated. This method integrates a special device of indentation to a universal measuring machine. The mentioned device allows introducing elongated indents allowing to diminish the absolute error of measurement. It must be noted that the present method offers the great advantage of avoiding both the specific equipment and highly qualified personnel, and their inherent high costs. In this work, the cutting tool geometry and high speed parameters are selected to introduce reduced plastic damage. Through the variation of the depth of cut, the stability of the shapes adopted by the residual strain and stress distributions is evaluated. The results show that the strain and stress distributions remain unchanged, compressive and small. Moreover, these distributions reveal a similar asymmetry when the gradients corresponding to conventional and climb cutting zones are compared.
Keywords: Residual strain, residual stress, high speed milling, indentation methods, aluminium alloys.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1477
6571 Tool Wear of Titanium/Tungsten/Silicon/Aluminum-based-coated end Mill Cutters in Millin Hardened Steel
Authors: Tadahiro Wada, Koji Iwamoto
Abstract:In turning hardened steel, polycrystalline cubic boron nitride (cBN) compacts are widely used, due to their higher hardness and higher thermal conductivity. However, in milling hardened steel, fracture of cBN cutting tools readily occurs because they have poor fracture toughness. Therefore, coated cemented carbide tools, which have good fracture toughness and wear resistance, are generally widely used. In this study, hardened steel (ASTM D2, JIS SKD11, 60HRC) was milled with three physical vapor deposition (PVD)-coated cemented carbide end mill cutters in order to determine effective tool materials for cutting hardened steel at high cutting speeds. The coating films used were (Ti,W)N/(Ti,W,Si)N and (Ti,W)N/(Ti,W,Si,Al)N coating films. (Ti,W,Si,Al)N is a new type of coating film. The inner layer of the (Ti,W)N/(Ti,W,Si)N and (Ti,W)N/(Ti,W,Si,Al)N coating system is (Ti,W)N coating film, and the outer layer is (Ti,W,Si)N and (Ti,W,Si,Al)N coating films, respectively. Furthermore, commercial (Ti,Al)N-based coating film was also used. The following results were obtained: (1) In milling hardened steel at a cutting speed of 3.33 m/s, the tool wear width of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool was smaller than that of the (Ti,W)N/(Ti,W,Si)N-coated tool. And, compared with the commercial (Ti,Al)N, the tool wear width of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool was smaller than that of the (Ti,Al)N-coated tool. (2) The tool wear of the (Ti,W)N/(Ti,W,Si,Al)N-coated tool increased with an increase in cutting speed. (3) The (Ti,W)N/(Ti,W,Si,Al)N-coated cemented carbide was an effective tool material for high-speed cutting below a cutting speed of 3.33 m/s.
Keywords: cutting, physical vapor deposition (PVD) coating system, hardened steel, tool wearProcedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1920
6570 Development of Fuzzy Logic and Neuro-Fuzzy Surface Roughness Prediction Systems Coupled with Cutting Current in Milling Operation
Authors: Joseph C. Chen, Venkata Mohan Kudapa
Abstract:Development of two real-time surface roughness (Ra) prediction systems for milling operations was attempted. The systems used not only cutting parameters, such as feed rate and spindle speed, but also the cutting current generated and corrected by a clamp type energy sensor. Two different approaches were developed. First, a fuzzy inference system (FIS), in which the fuzzy logic rules are generated by experts in the milling processes, was used to conduct prediction modeling using current cutting data. Second, a neuro-fuzzy system (ANFIS) was explored. Neuro-fuzzy systems are adaptive techniques in which data are collected on the network, processed, and rules are generated by the system. The inference system then uses these rules to predict Ra as the output. Experimental results showed that the parameters of spindle speed, feed rate, depth of cut, and input current variation could predict Ra. These two systems enable the prediction of Ra during the milling operation with an average of 91.83% and 94.48% accuracy by FIS and ANFIS systems, respectively. Statistically, the ANFIS system provided better prediction accuracy than that of the FIS system.
Keywords: Surface roughness, input current, fuzzy logic, neuro-fuzzy, milling operations.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 328
6569 Optimum Surface Roughness Prediction in Face Milling of High Silicon Stainless Steel
Authors: M. Farahnakian, M.R. Razfar, S. Elhami-Joosheghan
This paper presents an approach for the determination of the optimal cutting parameters (spindle speed, feed rate, depth of cut and engagement) leading to minimum surface roughness in face milling of high silicon stainless steel by coupling neural network (NN) and Electromagnetism-like Algorithm (EM). In this regard, the advantages of statistical experimental design technique, experimental measurements, artificial neural network, and Electromagnetism-like optimization method are exploited in an integrated manner. To this end, numerous experiments on this stainless steel were conducted to obtain surface roughness values. A predictive model for surface roughness is created by using a back propogation neural network, then the optimization problem was solved by using EM optimization. Additional experiments were performed to validate optimum surface roughness value predicted by EM algorithm. It is clearly seen that a good agreement is observed between the predicted values by EM coupled with feed forward neural network and experimental measurements. The obtained results show that the EM algorithm coupled with back propogation neural network is an efficient and accurate method in approaching the global minimum of surface roughness in face milling.
Keywords: cutting parameters, face milling, surface roughness, artificial neural network, Electromagnetism-like algorithm,Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2440
6568 Progressive Strategy of Milling by means of Tool Axis Inclination Angle
Authors: Sadílek M., Čep R.
This work deals with problems of tool axis inclination angles in ball-end milling. Tool axis inclination angle contributes to improvement of functional surface properties (surface integrity - surface roughness, residual stress, micro hardness, etc.), decreasing cutting forces and improving production. By milling with ball-end milling tool, using standard way of cutting, when work piece and cutting tool contain right angle, we have zero cutting speed on edge. At this point cutting tool only pushes material into the work piece. Here we can observe the following undesirable effects - chip contraction, increasing of cutting temperature, increasing vibrations or creation of built-up edge. These effects have negative results – low quality of surface and decreasing of tool life (in the worse case even it is pinching out). These effects can be eliminated with the tilt of cutting tool or tilt of work piece.
Keywords: CAD/CAM system, tool axis inclination angle, ballend milling, surface roughness, cutting forces.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1725
6567 Influence of Ball Milling Time on Mechanical Properties of Porous Ti-20Nb-5Ag Alloy
Authors: M. J. Shivaram, Shashi Bhushan Arya, Jagannath Nayak, Bharat Bhooshan Panigrahi
Abstract:Titanium and its alloys have become more significant implant materials due to their mechanical properties, excellent biocompatibility and high corrosion resistance. Biomaterials can be produce by using the powder metallurgy (PM) methods and required properties can tailored by varying the processing parameters, such as ball milling time, space holder particles, and sintering temperature. The desired properties such as, structural and mechanical properties can be obtained by powder metallurgy method. In the present study, deals with fabrication of solid and porous Ti-20Nb-5Ag alloy using high energy ball milling for different times (5 and 20 h). The resultant powder particles were used to fabricate solid and porous Ti-20Nb-5Ag alloy by adding space holder particles (NH4HCO3). The resultant powder particles, fabricated solid and porous samples were characterized by scanning electron microscopy (SEM). The compressive strength, elastic modulus and microhardness properties were investigated. Solid and porous Ti-20Nb-5Ag alloy samples showed good mechanical properties for 20 h ball milling time as compare to 5 h ball milling.
Keywords: Ball Milling, compressive strengths, microstructure, porous Titanium alloy.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 748
6566 Surface Roughness Optimization in End Milling Operation with Damper Inserted End Milling Cutters
Authors: Krishna Mohana Rao, G. Ravi Kumar, P. Sowmya
Abstract:This paper presents a study of the Taguchi design application to optimize surface quality in damper inserted end milling operation. Maintaining good surface quality usually involves additional manufacturing cost or loss of productivity. The Taguchi design is an efficient and effective experimental method in which a response variable can be optimized, given various factors, using fewer resources than a factorial design. This Study included spindle speed, feed rate, and depth of cut as control factors, usage of different tools in the same specification, which introduced tool condition and dimensional variability. An orthogonal array of L9(3^4)was used; ANOVA analyses were carried out to identify the significant factors affecting surface roughness, and the optimal cutting combination was determined by seeking the best surface roughness (response) and signal-to-noise ratio. Finally, confirmation tests verified that the Taguchi design was successful in optimizing milling parameters for surface roughness.
Keywords: ANOVA, Damper, End Milling, Optimization, Surface roughness, Taguchi design.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2204
6565 Development of Predictive Model for Surface Roughness in End Milling of Al-SiCp Metal Matrix Composites using Fuzzy Logic
Authors: M. Chandrasekaran, D. Devarasiddappa
Abstract:Metal matrix composites have been increasingly used as materials for components in automotive and aerospace industries because of their improved properties compared with non-reinforced alloys. During machining the selection of appropriate machining parameters to produce job for desired surface roughness is of great concern considering the economy of manufacturing process. In this study, a surface roughness prediction model using fuzzy logic is developed for end milling of Al-SiCp metal matrix composite component using carbide end mill cutter. The surface roughness is modeled as a function of spindle speed (N), feed rate (f), depth of cut (d) and the SiCp percentage (S). The predicted values surface roughness is compared with experimental result. The model predicts average percentage error as 4.56% and mean square error as 0.0729. It is observed that surface roughness is most influenced by feed rate, spindle speed and SiC percentage. Depth of cut has least influence.
Keywords: End milling, fuzzy logic, metal matrix composites, surface roughnessProcedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2039
6564 Effect of the Machine Frame Structures on the Frequency Responses of Spindle Tool
Authors: Yuan L. Lai, Yong R. Chen, Jui P. Hung, Tzuo L. Luo, Hsi H. Hsiao
Abstract:Chatter vibration has been a troublesome problem for a machine tool toward the high precision and high speed machining. Essentially, the machining performance is determined by the dynamic characteristics of the machine tool structure and dynamics of cutting process. Therefore the dynamic vibration behavior of spindle tool system greatly determines the performance of machine tool. The purpose of this study is to investigate the influences of the machine frame structure on the dynamic frequency of spindle tool unit through finite element modeling approach. To this end, a realistic finite element model of the vertical milling system was created by incorporated the spindle-bearing model into the spindle head stock of the machine frame. Using this model, the dynamic characteristics of the milling machines with different structural designs of spindle head stock and identical spindle tool unit were demonstrated. The results of the finite element modeling reveal that the spindle tool unit behaves more compliant when the excited frequency approaches the natural mode of the spindle tool; while the spindle tool show a higher dynamic stiffness at lower frequency that may be initiated by the structural mode of milling head. Under this condition, it is concluded that the structural configuration of spindle head stock associated with the vertical column of milling machine plays an important role in determining the machining dynamics of the spindle unit.
Keywords: Machine tools, Compliance, Frequency response function, Machine frame structure, Spindle unitProcedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2715
6563 Networked Implementation of Milling Stability Optimization with Bayesian Learning
Authors: C. Ramsauer, J. Karandikar, D. Leitner, T. Schmitz, F. Bleicher
Machining instability, or chatter, can impose an important limitation to discrete part machining. In this work, a networked implementation of milling stability optimization with Bayesian learning is presented. The milling process was monitored with a wireless sensory tool holder instrumented with an accelerometer at the TU Wien, Vienna, Austria. The recorded data from a milling test cut were used to classify the cut as stable or unstable based on a frequency analysis. The test cut result was used in a Bayesian stability learning algorithm at the University of Tennessee, Knoxville, Tennessee, USA. The algorithm calculated the probability of stability as a function of axial depth of cut and spindle speed based on the test result and recommended parameters for the next test cut. The iterative process between two transatlantic locations was repeated until convergence to a stable optimal process parameter set was achieved.
Keywords: Bayesian learning, instrumented tool holder, machining stability, optimization strategy.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 313
6562 A Systematic Approach for Identifying Turning Center Capabilities with Vertical Machining Center in Milling Operation
Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.
Keywords: Surface roughness, taguchi parameter design, turning center, turn-milling operations, vertical machining center.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2306
6561 The Effect of Rotational Speed and Shaft Eccentric on Looseness of Bearing
Authors: Chalermsak Leetrakool, Komson Jirapattarasilp
Abstract:This research was to study effect of rotational speed and eccentric factors, which were affected on looseness of bearing. The experiment was conducted on three rotational speeds and five eccentric distances with 5 replications. The results showed that influenced factor affected to looseness of bearing was rotational speed and eccentric distance which showed statistical significant. Higher rotational speed would cause on high looseness. Moreover, more eccentric distance, more looseness of bearing. Using bearing at high rotational with high eccentric of shaft would be affected bearing fault more than lower rotational speed. The prediction equation of looseness was generated by regression analysis. The prediction has an effected to the looseness of bearing at 91.5%.
Keywords: Bearing, Looseness, Rotational speed, EccentricProcedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1794
6560 Influence of High Speed Parameters on the Quality of Machined Surface
Authors: Jana Novakova, Lenka Petrkovska, Josef Brychta, Robert Cep, Lenka Ocenasova
The contribution is dealing with the influence of high speed parameters on the quality of machined surface. In general the principle of high speed cutting lies in achieving faster machine times with concurrent increase in accuracy and quality of the machined areas in largely irregular, mathematically hard to define shapes. High speed machining is a highly effective method of machining with the following goals: increasing of machining productivity, increasing of quality of the machined surface, improving of machining economy, improving of ecological aspects of machining. This article is based on an experiment performed by the Department of Machining and Assembly of the Faculty of Mechanical Engineering of VŠBTechnical University of Ostrava.
Keywords: High speed cutting, measurement, surface integrity, surface roughness, residual stress/Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1577
6559 Design of High-speed Modified Booth Multipliers Operating at GHz Ranges
Authors: Soojin Kim, Kyeongsoon Cho
Abstract:This paper describes the pipeline architecture of high-speed modified Booth multipliers. The proposed multiplier circuits are based on the modified Booth algorithm and the pipeline technique which are the most widely used to accelerate the multiplication speed. In order to implement the optimally pipelined multipliers, many kinds of experiments have been conducted. The speed of the multipliers is greatly improved by properly deciding the number of pipeline stages and the positions for the pipeline registers to be inserted. We described the proposed modified Booth multiplier circuits in Verilog HDL and synthesized the gate-level circuits using 0.13um standard cell library. The resultant multiplier circuits show better performance than others. Since the proposed multipliers operate at GHz ranges, they can be used in the systems requiring very high performance.
Keywords: multiplier, pipeline, high-speed, modified Boothalgorithm.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2573
6558 Role of Process Parameters on Pocket Milling with Abrasive Water Jet Machining Technique
Authors: T. V. K. Gupta, J. Ramkumar, Puneet Tandon, N. S. Vyas
Abrasive Water Jet Machining is an unconventional machining process well known for machining hard to cut materials. The primary research focus on the process was for through cutting and a very limited literature is available on pocket milling using AWJM. The present work is an attempt to use this process for milling applications considering a set of various process parameters. Four different input parameters, which were considered by researchers for part separation, are selected for the above application, i.e., abrasive size, flow rate, standoff distance and traverse speed. Pockets of definite size are machined to investigate surface roughness, material removal rate and pocket depth. Based on the data available through experiments on SS304 material, it is observed that higher traverse speeds gives a better finish because of reduction in the particle energy density and lower depth is also observed. Increase in the standoff distance and abrasive flow rate reduces the rate of material removal as the jet loses its focus and occurrence of collisions within the particles. ANOVA for individual output parameter has been studied to know the significant process parameters.
Keywords: Abrasive flow rate, surface finish, abrasive size, standoff distance, traverse speed.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 4093
6557 Synthesis of Y2O3 Films by Spray Coating with Milled EDTA·Y·H Complexes
Authors: Keiji Komatsu, Tetsuo Sekiya, Ayumu Toyama, Atsushi Nakamura, Ikumi Toda, Shigeo Ohshio, Hiroyuki Muramatsu, Hidetoshi Saitoh, Atsushi Nakamura, Ariyuki Kato
Yttrium oxide (Y2O3) films have been successfully deposited with yttrium-ethylenediamine tetraacetic acid (EDTA·Y·H) complexes prepared by various milling techniques. The effects of the properties of the EDTA·Y·H complex on the properties of the deposited Y2O3 films have been analyzed. Seven different types of the raw EDTA·Y·H complexes were prepared by various commercial milling techniques such as ball milling, hammer milling, commercial milling, and mortar milling. The milled EDTA·Y·H complexes exhibited various particle sizes and distributions, depending on the milling method. Furthermore, we analyzed the crystal structure, morphology and elemental distribution profile of the metal oxide films deposited on stainless steel substrate with the milled EDTA·Y·H complexes. Depending on the milling technique, the flow properties of the raw powders differed. The X-ray diffraction pattern of all the samples revealed the formation of Y2O3 crystalline phase, irrespective of the milling technique. Of all the different milling techniques, the hammer milling technique is considered suitable for fabricating dense Y2O3 films.
Keywords: Powder sizes and distributions, Flame spray coating techniques, Yttrium oxide.Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2230