Papers by Keyword: Milling Process

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Authors: Guo Hua Qin, S.Q. Xin, Dong Lu, Yi Ming Rong
Abstract: In the field of aeronautical and astronautical manufacturing, milling is a basic machining process by which a surface is generated by progressive chip removal. Therefore, this paper reports a complete procedure of the finite element model for the 3D oblique milling process using the commercial software package ABAQUS. Effect of various parameters on cutting forces is mainly discussed. The model correctly exhibits the observed transition from small to large force with increasing cutting speed and cutting depth.
Authors: Z. Yang, T. Huang, Y.M. Yang
Abstract: One of key approaches to improve the productivity is to control with constant force in the milling process by adjusting the feed rate. In order to overcome the mismatch model occurred in adaptive control and inaccurate deducing regulation in fuzzy logic control, a three-layer BP neural network is designed for tracing reference force. First of all, control arithmetic is given, and a series of simulation work is achieved to determine the study factor. At last, aimed at two working conditions with abrupt and gradual change of cutting depth, the correctness and effectiveness of the neural network controller are proved by experiments.
Authors: Dun Wen Zuo, Hong Feng Wang, Hong Miao, H.J. Wang
Abstract: Milling process of jointing blank of 7022 aluminum alloy was simulated by ANSYS. The results show that the maximum residual tensile stress and pressure stress are mainly concentrated in the jointing seam zone when the jointing blank is milled. The milling deformation of jointing blank is shown as “wave” shape. The milling deformation of key eye side is shown upwarp. The jointing initiating terminal is shown downward displacement. The maximum downward displacement is present to the middle of jointing seam central line. In additional, the milling deformation along sheet length direction is shown outward extension.
Authors: Ahmed Sahib Mahdi, Mohammad Sukri Mustapa, Mahmod Abd Hakim Mohamad, Abdul Latif M. Tobi, Muhammad Irfan Ab Kadir, Mohd Arif Samsi
Abstract: The micro-hardness and compression of recycling aluminum alloy AA6061 were investigated as a function of the different microstructure and constituent powder metallurgy method. Five specimens were selected to investigate the compression strength and microhardness. The first, as fabricated specimen (as compacted), the second was as heat treated by quenching and aging process. Three specimens were mixed with Graphite particles as a reinforcement material. Compression strength values were tested for the specimens as fabricated and heat treated which were 195 and 300 MPa, respectively. The improvement ratio was 52% for the specimen as heat treated. On the other hand, high wear resistance was given by the specimen as heat treated, whereas, the lower wear strength was at the specimen mixed with 4.5% Graphite. These results were attributed to that the wear resistance related to the microhardness value.
Authors: M.C. Hwang, Joon Young Koo, Yong Ki Choi, Hyun Jung Kim, Jeong Suk Kim
Abstract: Recently, as the automotive and aerospace industry research has focused one weight lightening, the use of functional aluminum alloys has been increasing. Aluminum alloys are effective materials because of their high specific strength and high stiffness ratio. However, machining deformation and heat deflection can occur depending on the machining type. Owing to these difficult-to-cut characteristics, it is necessary to monitor the machined surface quality of aluminum alloys. In this paper, we study the correlation between surface quality, namely burr formation and surface roughness, related to cutting parameters and signals obtained from multiple sensors. The output signals are measured by an acoustic emission (AE) sensor and an accelerometer and are analyzed in the signal frequency domain. By using the wavelet transform of analyzed signals, we determine the correlation between surface quality and signals. Based on this investigation, a surface quality monitoring system can be suggested.
Authors: Bing Han, Cheng Zu Ren, X.Y. Yang, Guang Chen
Abstract: The deflection of Aluminum alloy thin-wall workpiece caused by the milling force leads to additional machining errors and reduces machining accuracy. In this paper, a set of experiments of milling thin-wall workpiece were carried out to study the deflection of thin-wall workpiece. The workpieces, with different types of material and different thicknesses, were machined on CNC machining center. The deflections of workpiece were measured by a three-coordinate measuring machine. Effects of Aluminum alloy material and thickness on deflection are discussed based on the experimental data.
Authors: Klaus Weinert, Dirk Biermann, Michael Kersting, Sven Grünert
Abstract: Different possible reasons for defects have to be considered in machining light-weight aluminum structures. In the machining process, the cutting power affecting the workpiece leads to a thermo-mechanical load that can cause undesirable workpiece deformations and thus shape deviations. Moreover, the microstructure and the machined surface can be influenced, which is detrimental to the later application of the structures. Previously conducted experimental and simulative investigations, estimated the circular milling process to be the most suitable machining operation that provides the best compromise between mechanical and thermal loads compared to drilling operations [1,2]. In this paper the results of machining end-cross-sections of an aluminum profile are presented. The machining was obtained by a milling process, which is demanding, because of the low profile stiffness. For this process it is important to know the effects of machining in view of the shape deviations. By means of a Finite-Element-Analysis the deformations of the profile web can be calculated as well as validated by experiments. Based on these results, the appropriate process parameter values for end machining can be defined.
Authors: Zhi Wei, Ji Hong Jia, Mei Lin Gu, Chao Zuo, Xing Zhen Jin
Abstract: This paper describes the experimental system of milling force, the tool geometrical feature and the certain experimental condition in the section of experimental case, which also makes an explanation about the designing of experimental case and the analysis of the experimental data. It also represents the relationship between coefficients associated with the milling process and the milling force applied on the tool in detail. A finite element method is used to make an explicit analysis on the stress and deformation of the milling tool under the application of certain milling force. Finally, a summary is made to conclude the study and its results.
Authors: Y. Zhao, Feng Xu, Dun Wen Zuo, Jing Kang
Abstract: In this paper, by adopting an equivalent geometry model of the cutting layer, a three-dimensional (3D) finite element model was built to investigate the milling of Ti-6Al-4V. The chip separating process was simulated by Arbitrary Lagrangian-Eulerian (ALE) method and automatic re-meshing technology. The experiments of milling Ti-6Al-4V were carried out to verify finite element model of milling process. The comparisons of the predicted cutting forces and the measured forces showed reasonable agreement. Finally, the finite element model was used to predict the chip deformation and the three-dimensional distribution of cutting force, stress and temperature in milling Ti-6Al-4V.
Authors: Shao Gang Liu, Qiu Jin
Abstract: This paper presents a analytical method to calculate the minimum clamping force to prevent slippage between the workpiece and spherical-tipped fixture elements during milling process. After the contact deformation between the workpiece and spherical-tipped fixture element is determined, the relationships between the workpiece displacement and the contact deformations are obtained. Based on the static equilibrium equations, these equations are combined and linear equations are obtained to calculate the tangential contact forces between the workpiece and spherical-tipped fixture element. According to the maximum tangential contact force, the minimum clamping force to prevent slippage between the workpiece and spherical-tipped fixture elements is calculated. At last, this method is illustrated with a simulation example.
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