The Processing of the Profile Surface of the Work-Pieces, Characterized by Low Rigidity

Abstract:

This work indicates that the prediction of the geometric indicators of the quality of the machined surface in the design of technological operations for milling a profile surface of work-pieces with low rigidity is possible, on the basis of an analysis of the elastic displacements of the technological system elements, the flexural rigidity of the work-piece as a function of its initial dimensions, the locating chart and the physical and mechanical characteristics of the material being processed. The article describes the characteristics of the elements of the technological system for the profile milling of work-pieces of low rigidity; The analytical dependencies linking the elastic displacements of the work-piece during the processing of various wood species with elements of the milling mode and the design parameters of the mill are given. Extreme total elastic displacements of the technological system during the cutting process are determined. Mathematical models of the maximum geometric error of the machined surface, as a function of the work-piece's flexural rigidity and the spindle unit, are established. Based on the results of the analysis, recommendations for improving the accuracy of the product were developed.

• Periodical: Solid State Phenomena (Volume 299)
• Pages: 852-860
• DOI: https://doi.org/10.4028/www.scientific.net/SSP.299.852
• Online since: January 2020
• Authors: Anatoly A. Fomin*, Vladimir G. Gusev, Nail F. Timerbaev
• Keywords: Accuracy, Elastic Displacement, Milling, Peripheral Segment, Profile Surface, Rigidity

References

[1] G. Goch, et al, Review of non-destructive measuring methods for the assessment of surface integrity: a survey of new measuring methods for coatings, layered structures and processed surfaces, Precision Engineering, 23(1) (1999) 9-33.

DOI: 10.1016/s0141-6359(98)00021-x

[2] C.A. Van Luttervelt, et al, Present situation and future trends in modelling of machining operations progress report of the CIRP Working Group 'Modelling of Machining Operations, CIRP Annals-Manufacturing Technology, 47(2) (1998) 587-626.

DOI: 10.1016/s0007-8506(07)63244-2

[3] I.S. Jawahir, C.A. Van Luttervelt, Recent developments in chip control research and applications, CIRP Annals-Manufacturing Technology, 42(2) (1993) 659-693.

DOI: 10.1016/s0007-8506(07)62531-1

[4] A.A. Fomin, Kinematics of surface formation in milling Russian Engineering Research, 33(11) (2013) 660-662.

DOI: 10.3103/s1068798x13110099

[5] R.D. Young, T.V. Vorburger, E.C. Teague, In-process and on-line measurement of surface finish, CIRP Annals-Manufacturing Technology, 29(1) (1980) 435-440.

DOI: 10.1016/s0007-8506(07)61366-3

[6] A.A. Fomin, V.G. Gusev, Spindle Rigidity in Milling Blanks with Nonuniform Properties, Russian Engineering Research, 33(11) (2013) 646-648.

DOI: 10.3103/s1068798x13110087

[7] X. Su, et al, Predictive model of milling force for complex profile milling. The International Journal of Advanced Manufacturing Technology, 87(5) (2016) 1653-1662.

DOI: 10.1007/s00170-016-8589-1

[8] T. Ohuchi, Y. Murase, Milling of wood and wood-based materials with a computerized numerically controlled router IV: development of automatic measurement system for cutting edge profile of throw-away type straight bit. Journal of wood science, 51(3) (2005) 278-281.

DOI: 10.1007/s10086-004-0663-x

[9] A.A. Fomin, et al., Mechanical treatment of raw waste lumber an effective way to preserve the ecology and resources IOP Conference Series: Materials Science and Engineering 142(1) (2016) 012091.

DOI: 10.1088/1757-899x/142/1/012091

[10] A. Banerjee, H.Y. Feng, E.V. Bordatchev, Geometry of chip formation in circular end milling. The International Journal of Advanced Manufacturing Technology, 59(1-4) (2012) 21-35.

DOI: 10.1007/s00170-011-3478-0

[11] I.A. Popov, A.V. Shchelchkov, Y.F. Gortyshov, et al., High Temp, 55(4) (2017) 524.

[12] I.V. Anisimova, Y.F. Gortyshov, V.N. Ignat'ev, Russ. Aeronaut, 59 (2016) 414.

[13] O.V. Kolenchenko, Influence of the milling conditions on the deformation and quality of the machined surface. Russian Engineering Research, 30(8) (2010) 839-844.

DOI: 10.3103/s1068798x1008023x

[14] Yu.S. Stepanov, G.V. Barsukov, S.G. Bishutin, Technological fundamentals for efficiency control of hydroabrasive cutting Procedia Engineering, 150 (2016) 717-725.

DOI: 10.1016/j.proeng.2016.07.093

[15] D.I. Volkov, A.A. Koryazhkin, Russ. Engin. Res., 32 (2012) 698.

[16] D.I. Volkov, A.A. Koryazhkin, Adaptive belt grinding of gas-turbine blades, Russian Engineering Research, 34(1) (2014) 37-40.

DOI: 10.3103/s1068798x14010171

[17] A.A. Fomin, V.G. Gusev and Z.G. Sattarova, Geometrical errors of surfaces milled with convex and concave profile tools, Solid State Phenomena, 284 (2018): 281-288.

DOI: 10.4028/www.scientific.net/ssp.284.281

[18] D.B. Prosvirnikov, et al., Modelling heat and mass transfer processes in capillary-porous materials at their grinding by pressure release, Proceedings of 2017, ICIEAM 2017, art. no. 8076443.

DOI: 10.1109/icieam.2017.8076443

[19] V.A. Saldaev, et al., Equipment for the production of wood-polymeric thermal insulation materials IOP Conference Series: Materials Science and Engineering, 142(1) (2016) 012097.

DOI: 10.1088/1757-899x/142/1/012097

[20] A.R. Sadrtdinov, et al., The development of equipment for the disposal of solid organic waste and optimization of its operation IOP Conference Series: Materials Science and Engineering 142(1) (2016) 012095.

DOI: 10.1088/1757-899x/142/1/012095

[21] A.A. Fomin, Microgeometry of surfaces after profile milling with the use of automatic cutting control system. Proceedings of 2017 International Conference on Industrial Engineering, Applications and Manufacturing, ICIEAM 2017, art. no. 8076117.

DOI: 10.1109/icieam.2017.8076117

[22] Y. Li, J.W. Fan, D.J. Chen, X.F. Wang, Modeling and Simulation of Formed Milling Cutter for Screw Based on Non-instantaneous Envelope Method. In Advances in Automation and Robotics, 2 (2011) 61-68.

DOI: 10.1007/978-3-642-25646-2_8

[23] A.A. Fomin, Limiting product surface and its use in profile milling design operations. Solid State Phenomena, 265 (2017) 672-678.

DOI: 10.4028/www.scientific.net/ssp.265.672

[24] A.R. Sadrtdinov, et al., The mathematical description of the gasification process of woody biomass in installations with a plasma heat source for producing synthesis gas. IOP Conference Series: Materials Science and Engineering 124(1) (2016) 012092.

DOI: 10.1088/1757-899x/124/1/012092

[25] A.A. Fomin, V.G. Gusev, Safe machining of blanks with nonuniform properties Russian Engineering Research, 33(10) (2013) 602-606.

DOI: 10.3103/s1068798x13100043

[26] L. Fernández-Robles, G. Azzopardi, E. Alegre, N. Petkov, Cutting edge localisation in an edge profile milling head. In International Conference on Computer Analysis of Images and Patterns, (2015) 336-347.

DOI: 10.1007/978-3-319-23117-4_29

[27] Y. Namba, H. Tsuwa, Geometrical adaptive control in profile milling by CNC system. In Proceedings of the Seventeenth International Machine Tool Design and Research Conference, Macmillan Education UK, (1977) 67-74.

DOI: 10.1007/978-1-349-81484-8_9

[28] A.A. Fomin, Kinematics of surface formation in milling Russian Engineering Research 33(11) (2013) 660-662.

DOI: 10.3103/s1068798x13110099

[29] A.A. Fomin, Determining undeformed chip thickness models in milling and its verification during wood processing, Solid State Phenomena, 265 (2017) 598-605.

DOI: 10.4028/www.scientific.net/ssp.265.598

[30] N.F. Timerbaev, et.al., Application of software solutions for modeling and analysis of parameters of belt drive in engineering. IOP Conf. Ser.: Earth Environ. Sci., 87(8) (2017) 082047.

DOI: 10.1088/1755-1315/87/8/082047

[31] G. Totis, et al., Upgraded stability analysis of milling operations by means of advanced modeling of tooling system bending. International Journal of Machine Tools and Manufacture, 113 (2017) 19-34.

DOI: 10.1016/j.ijmachtools.2016.11.005

[32] Michael V. Drapalyuk, et al., IOP Conf. Ser.: Mater. Sci. Eng., 142 (2016) 012090.

[33] R. Safin, et al., A mathematical model of thermal decomposition of wood in conditions of fluidized bed, Acta Facultatis Xylologiae Zvolen res Publica Slovaca, 58(2) (2016) 141-148.

[34] C. Li, X. Chen, Y. Tang, L. Li, Selection of optimum parameters in multi-pass face milling for maximum energy efficiency and minimum production cost. Journal of Cleaner Production, 140 (2017) 1805-1818.

DOI: 10.1016/j.jclepro.2016.07.086

[35] N.F. Timerbaev, A.R. Sadrtdinov and R.G. Safin, Software systems application for shafts strength analysis in mechanical engineering. Procedia Engineering 206 (2017) 1376-1381.

DOI: 10.1016/j.proeng.2017.10.648

[36] Dimov Yuriy, Dmitriy Podashev. Optimization of Edge Rounding with Elastic Abrasive Tools // International Journal of Engineering and Technology (IJET). Dec 2015-Jan 2016. – vol. 7, №6. – P. 2001-2007.

[37] V.V. Stepanov, et al., Composite Material for Railroad Tie, Solid State Phenomena, 265 (2017) 587-591.

DOI: 10.4028/www.scientific.net/ssp.265.587

[38] L. Fernández-Robles, et al., Machine-vision-based identification of broken inserts in edge profile milling heads, Robotics and Computer-Integrated Manufacturing, 44 (2017) 276-283.

DOI: 10.1016/j.rcim.2016.10.004

[39] D.B. Prosvirnikov, et al., IOP Conf. Ser.: Mater. Sci. Eng., 221(1) (2017) 012009.

[40] N.F. Timerbaev, D.F. Ziatdinova, R.G. Safin and A.R. Sadrtdinov, Gas purification system modeling in fatty acids removing from soapstock, Proceedings of 2017 International Conference on Industrial Engineering, Applications and Manufacturing, ICIEAM 2017, art. no. 8076418.

DOI: 10.1109/icieam.2017.8076418

[41] O.V. Kolenchenko, Influence of the milling conditions on the deformation and quality of the machined surface. Russian Engineering Research, 30(8) (2010) 839-844.

DOI: 10.3103/s1068798x1008023x

[42] D.B. Prosvirnikov, et al., IOP Conf. Ser.: Mater. Sci. Eng., 221(1) (2017) 012010.

[43] V.A. Lashkov, et al., IOP Conf. Ser.: Mater. Sci. Eng., 124 (2016) 012111.

[44] D.V. Tuntsev, et al., The mathematical model of fast pyrolysis of wood waste. Proceedings of 2015, MEACS 2015. art. no. 7414929.

[45] R.G. Safin et al., Technology of Wood Waste Processing to Obtain Construction Material, Solid State Phenomena, 265 (2017) 245-249.

DOI: 10.4028/www.scientific.net/ssp.265.245

[46] Dimov Yu. V., Podashev D.B. Efficient Machining by Elastic Abrasive Wheels. Russian Engineering Research. – 2017. – vol. 37, №7. – P. 655-659.

DOI: 10.3103/s1068798x17070097

[47] I.A. Popov, et al., Cooling systems for electronic devices based on the ribbed heat pipe. Russian Aeronautics (Iz VUZ) 58(3) (2015) 309-314.

DOI: 10.3103/s1068799815030101

[48] Dimov Yu. V., Podashev D.B. Edge Forces in Machining by Abrasive Brushes. Russian Engineering Research. – 2017. – vol. 37, №2. – P. 117-121.

DOI: 10.3103/s1068798x17020058

[49] V.E. Ovcharenko, K.V. Ivanov, Y.F. Ivanov, et al., Russ Phys J., 59 (2017) 2114.

[50] J. Wang, J. Qian, E. Ferraris, D. Reynaerts, In-situ process monitoring and adaptive control for precision micro-EDM cavity milling. Precision Engineering, 47 (2017) 261-275.

DOI: 10.1016/j.precisioneng.2016.09.001

[51] A. Bardovsky, A. Gerasimova, A. Aydunbekov, The principles of the milling equipment improvement, MATEC Web of Conferences, 224, (2018).

DOI: 10.1051/matecconf/201822401019

[52] A.A. Gerasimova, A.G. Radyuk, A.E. Titlyanov, Wear-resistant aluminum and chromonickel coatings at the narrow mold walls in continuous-casting machines, Steel in Translation, 46 (7) (2016) 458- 462.

DOI: 10.3103/s0967091216070068

[53] A.A. Gerasimova, A.G. Radyuk, The improvement of the surface quality of workpieces by coating, CIS Iron and Steel Review, (9) (2014) 33-35.

[54] R.Y. Nekrasov, Y.A. Tempel, U.S. Putilova, Precision CNC machining and ways to achieve it, MATEC Web of conferences ICMTMTE, 224 (2018) 30.

DOI: 10.1051/matecconf/201822401048

[55] R.Y. Nekrasov, Y.A. Tempel, O.A. Tempel, I.V. Soloviev, A.I. Starikov, Numerical studies to determine spatial deviations of a workpiece that occur when machining on CNC machines, MATEC Web of conferences ICMTMTE, 129 (2017) 7.

DOI: 10.1051/matecconf/201712901072

[56] R.Y. Nekrasov, Y.A. Tempel, A.I. Starikov, N.A. Proskuryakov, Fuzzy Controllers in the Adaptive Control System of a CNC Lathe, Russian Engineering Research, 38(3) (2018) 220-222.

DOI: 10.3103/s1068798x18030188

[57] F.V. Grechnikov, A.F. Rezchikov, O.V. Zakharov, Iterative Method of Adjusting the Radius of the Spherical Probe of Mobile Coordinate-Measuring Machines When Monitoring a Rotation Surface. Measurement Techniques, 61 (2018) 347-352.

DOI: 10.1007/s11018-018-1432-3

[58] A.F. Rezchikov, A.V. Kochetkov, and O.V. Zakharov, Mathematical models for estimating the degree of influence of major factors on performance and accuracy of coordinate measuring machines. MATEC Web Conf., 129 (2017) 01054.

DOI: 10.1051/matecconf/201712901054

[59] O.V. Zakharov, A.V. Kochetkov, Minimization of the systematic error in centerless measurement of the roundness of parts. Measurement Techniques, 58 (2016) 1317-1321.

DOI: 10.1007/s11018-016-0892-6

[60] V. Yemelyanov, T. Tochilkina, E. Vasilieva, A. Nedelkin, E. Shved, Computer diagnostics of the torpedo ladle cars, AIP Conference Proceedings, 020008, Vol. 2034, (2018).

DOI: 10.1063/1.5067351

[61] V.A. Yemelyanov, Intelligent information technology of visual information processing for metals diagnostics, Naukovyi Visnyk Natsionalnoho Hirnychoho Universytetu, 4 (2014) 66-73.

DOI: 10.29202/nvngu

[62] O.V. Sharkov, S.I. Koryagin, N.L. Velikanov, Design Models for Shaping of Tooth Profile of External Fine-Module Ratchet Teeth // IOP Conference Series: Materials Science and Engineering, 124 (2016) 012165.

DOI: 10.1088/1757-899x/124/1/012165

[63] O.V. Sharkov, S.I. Koryagin, N.L. Velikanov, Shaping Cutter Original Profile for Fine-module Ratchet Teeth Cutting, IOP Conference Series: Materials Science and Engineering, 327 (2018) 042102.

DOI: 10.1088/1757-899x/327/4/042102

[64] V.E. Gromov, V.E. Kormyshev, A.M. Glezer, etc., Microstructure and wear properties of Hardox 450 steel surface modified by Fe-C-Cr-Nb-W powder wire surfacing and electron beam treatment, IOP Conference Series: Materials Science and Engineering, 411(1) (2018).

DOI: 10.1088/1757-899x/411/1/012024

[65] S. Konovalov, X. Chen, V. Sarychev, etc., Mathematical modeling of the concentrated energy flow effect on metallic materials, Metals, 7(1) (2017).