Papers by Keyword: High Speed Machining (HSM)

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Authors: You Peng You, Jun He
Abstract: Smooth kinematic profiles are very important for high speed curve machining. During parametric interpolation, simple adaptive feedrate with confined contour error may cause acceleration and jerk to fluctuate acutely. To avoid the undesirable influence, an interpolation algorithm for parametric curves with smooth kinematic profiles is presented. The interpolator consists of three parts, look-ahead module, feedrate planning module and interpolation module. In look-ahead module, a pre-interpolator is designed to produce the required feedrate profile considering chord error. By feedrate planning, a smooth feedrate profile with confined acceleration and jerk is schemed based on bell-shape ACC/DEC profile by feedrate profile matching and feedrate profile synthesis. Then the parametric curve can be interpolated with the planned feedrate in interpolation module. Simulation results have been also provided to illustrate that the proposed interpolator can generate smooth kinematic profiles required for the high tracking accuracy at high speed with confined chord error, acceleration and jerk, and can be used for high speed and precision curve machining.
Authors: Yu Jun Cai, Chun Zheng Duan, Li Jie Sun
Abstract: A strategy of toolpath generation based on Tool-Zmap geometric model has been proposed to achieve efficient finish machining of mold cavity. Considering cutting tool wear, the finish machining of mold cavity was performed using variable cutting tools of different diameter. Each cutting tool only cuts the corresponding area to avoid identifying machining characteristic and poor rigidity of cutting tool during high speed machining. Finally, the validity of presented strategy was experimentally affirmed by a machining example.
Authors: Wei Wu Zhong, Dong Biao Zhao, Xi Wang, Hui Yu
Abstract: Green manufacturing is the theme of manufacturing industry in the 21st century. The environment can be seriously polluted by a large quantity of waste cutting fluid .In manufacturing industry, it’s critical to restrict the quantity of waste cutting fluid poured in the environment in order to assure a green earth. Cutting temperature has a major impact on processing quality. A stable cutting temperature means a high quality process. Cutting temperature is also a comprehensive embodiment of process state. In order to control cutting temperature in an appropriate level, an adaptive fuzzy control system is developed to control the flow of cutting fluid injected to machining tool and workpiece which can not only reduce the consumption of cutting fluid but also ensure process quality. Simulation and experiment results show that this control system can achieve the desired purpose.
Authors: Su Yu Wang, Jun Zhao, Xing Ai
Authors: Chun Zheng Duan, Liang Chi Zhang, Hai Yang Yu, Min Jie Wang
Abstract: Adiabatic shear banding during high speed machining is important to understand material removal mechanisms. This paper investigates the microstructure of adiabatic shear bands (ASBs) in the serrated chips produced during the high speed machining of AISI 1045 hardened steel. Optical microscope, scanning electronic microscope(SEM) and transmission electronic microscope(TEM) were used to explore the microstructural characteristics. It was found that there are two types of adiabatic shear bands. One is the deformed adiabatic shear band composed of a significantly deformed structure generated in a range of low cutting speeds, and the other is the transformed adiabatic shear band composed of very small equiaxed grains generated under high cutting speeds. The results indicated that the deformed band has a tempered martensite structure that formed through large plastic deformation and the transformed band has experienced a dynamic recrystallization process.
Authors: Yan Ming Quan, Joseph A. Arsecularatne, Liang Chi Zhang
Abstract: High speed machining (HSM) is finding wider applications due to its economic advantages, such as faster material removal rates, and its technological merits, such as improved surface finish. Nevertheless, the application of HSM also brings about some undesirable results. For example, the tool life and surface integrity of a machined component are greatly affected by the large amount of heat generated, but heat dissipation during an HSM has not been well understood. This paper aims to achieve a quantitative understanding of the heat dissipation in HSM using a bar turning configuration. Based on the calorimetric method and utilizing water as the heat transfer medium, the temperature rise in water was measured to determine the fractions of heat dissipated into the chips, the tool and the workpiece during machining. The obtained results show that the chips take the largest portion of the heat generated and this fraction increases with the increase in feed.
Authors: Erween Abdul Rahim, Hiroyuki Sasahara
Abstract: Nowadays, an increase on demands of aerospace components has led to implementation of high speed machining (HSM). The principal factors in the performance of aerospace materials are strength-to-weight ratio, fatigue life, fracture toughness, survivability and of course, reliability. However, when HSM is coupled with dry or near dry machining, it will present considerable technical challenges to the manufacturing sector especially when the integrity of the machined surface is concerned. In this investigation, the effect of high speed drilling (HSD) conditions on the performance and surface integrity of Inconel 718 were studied. Hole was drilled individually using TiAlN coated carbide insert drill (14 mm in diameter) under minimum quantity of lubrication (MQL) condition. Results showed that uniform flank wear and chipping were the dominant tool failure modes. Moreover, the results showed an increase in cutting temperature with increasing cutting speed and feed rate. Thrust force and torque decreased linearly with the increasing cutting speed but significantly increased when higher feed rate is employed. Cutting speed significantly influenced the distribution of surface roughness value. Variations of hardness readings were recorded beneath the machined surfaces, they were due to the hardening effects caused by concentration of high temperature and stresses on the workpiece.
Authors: Xue Hui Wang, Ming Jun Feng, Shi Cheng Liu
Abstract: For taking advantage of high speed machining(HSM) in complex curved surfaces as impeller, the virtual manufacturing technology is adopted before the real machining, which can eliminate tool collision interference phenomenon of the trial cutting, avoid complicated process of trial test , forecast machining results efficiently. The simulation tests were proceeded to the each impeller procedure NC program by using the VERICUT virtual manufacturing soft to modeling five-axis machine tool HSM600U, and the result compared with the real machining is identical with one other. So it is tested that applying this technology can forecast the machining process truly.
Authors: P.K. Mehrotra
Authors: Song Zhang, Xing Ai, Wei Xiao Tang, J.G. Liu
Abstract: High-speed machining has become mainstream in machining manufacturing industry. In industries such as moldmaking and aerospace, it has become the norm rather the exception. The centrifugal force increases as the square of the speed. At rotational spindle speeds of 6,000 r/min and higher however, centrifugal force from unbalance becomes a damaging factor and it reduces the life of the spindle and the tool, as well as diminishes the quality of the finished product. Under high rotational speed, good balance becomes issue. High-speed machining experimental results shown that a well-balanced tool/toolholder assembly could obviously improve machining quality, extend tool life and shorten downtime for spindle system maintenance etc.
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