Analysis of Different Parameters on Tool Path for Machining Sculptured Surfaces (original) (raw)
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Nowadays, the using of CAD/CAM systems in order to produce CNC milling machine's program can significantly decrease the programming and production time and can optimize the parameters of milling process. In these systems, the better selection of the roughing cut strategy should be proportionate with the geometry of surfaces. In this paper the variety of strategies in the roughing cut of convex and concave surfaces on the basis of revolve, sweep and loft are compared in two powerful software systems. The effect of two cutting tools, which are ball nosed and end mill on the aforementioned surfaces, is also investigated. The strategies are raster area clear, offset area clear, parallel and radial and the two powerful softwares are Master CAM and Power Mill. The aim of this paper is to compare and contrast the variety of strategies in two softwares in terms of machining time, tool kind and surface quality. Finally, the optimum strategy and tool kind are presented.
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2016
The trend towards automation of production equipment is having great demands from people. Since the early 1970s, manufacturers have worked to increase productivity, quality, process capability, reliability and flexibility. They used technologies to improve quality and productivity. This study studies the differences of a few CNC milling program – relating to time scale and machining accuracy. For experiment, a few programs are being written to machining a simple product. Each program has its own features. By running all the written programs, the effectiveness and goodness of each program could be analyzed. On the other hand, by machining the product and testing them, the product accuracy also can be analyzed. The results show that, the number of command lines will affect the simulation time. More command lines in the program will need more time in running the simulation. Besides that, results show that using the Canned Cycle command will give a more accurate machining compared to th...
Effect of Machining Parameters and Optimization of Machining Time
The objective of this research is to select the machining parameters and its cutting conditions to increase the productivity and minimize of total machining time and machining cost. A significant improvement in process may lead to increase in the process efficiency and low cost of manufacturing. In this research, Spindle speed, Feed rate, Depth of cut and End relief angle are considered as input parameters for facing operation of the A22E Bimetal bearing material using M42 HSS tool material. A second order mathematical model was developed by using Design of Experiments (DoE) of Response Surface Methodology (RSM) to predict the machining time of Bimetal bearing material. The Analysis of Variance (ANOVA) was used to study the performance characteristics in facing operation. The direct and interaction effects of the machining parameters were also analyzed using Design Expert software. The values of Prob > F less than 0.05 indicate model terms are significant. The Genetic Algorithm (GA) was trained and tested by using MATLAB 7.0. The GA recommends 1.169 seconds as the best minimum predicted machining time value. The confirmatory test shows the predicted values and experimental values were very close and good agreement.
Precision Sculptured Surface CNC Machining Using Cutter Location Data
Key Engineering Materials, 2016
Industrial parts with sculptured surfaces are typically, manufactured with the use of CNC machining technology and CAM software to generate surface tool paths. To assess tool paths computed for 3-and 5-axis machining, the machining error is evaluated in advance referring to the parameter controlling the linearization of high-order curves, as well as the scallop yielded as a function of radial cutting engagement parameter. The two parameters responsible for the machining error are modeled and corresponding cutter location data for tool paths are utilized to compare actual trajectories with theoretical curves on a sculptured surface (SS) assessing thus the deviation when virtual tools are employed to maintain low cost; whilst ensuring high precision cutting. This operation is supported by applying a flexible automation code capable of computing the tool path; extracting its CL data; importing them to the CAD part and finally projecting them onto the part's surface. For a given tolerance, heights from projected instances are computed for tool paths created by changing the parameters under a cutting strategy, towards the identification of the optimum tool path. To represent a global solution rough machining is also discussed prior to finish machining where the new proposals are mainly applied.
A Review on Optimisation of CNC End Milling Machining Parameters
During the machining operation, it is essential to have a proper selection of machining parameters. Nowadays machining parameters are mainly selected on the basis of previous work experience of the process planner or thumb rule or machining data handbook. All these techniques are very tedious and time-consuming. Therefore, there is a need to develop a model that could able to find the optimal machining parameters for the required surface Quality characteristics machining. In this work, an attempt is made to review the literature on the effect of machining parameters such as Cutting speed, feed rate, Depth of cut, nose radius, coolant flow, tool wear, environmental conditions, etc. to obtain the optimum machining parameters and the extents of the significant influence of the process parameters for CNC End Milling operations. Many researchers have used the various techniques such as Taguchi method, Design of Experiments (DOE), Response surface methodology (RSM), Grey Relational Analysis (GRA), Artificial Neural Network (ANN), Fuzzy Logic, Central Composite Design (CCD), Genetic Algorithm (GA), gravitational search algorithm (GSA) and so on have become very popular due to its versatile usage in various field of engineering applications especially in machining problems.
Three and five axes milling of sculptured surfaces
Journal of Materials Processing Technology, 2000
The aim of this work is the analysis of the influence of the milling parameters on the surface finish. This work is of interest to both science and industry. On one hand, it tries to reduce the manual polishing time, which represents a high percentage of the production time of moulds. On the other hand, while the literature mainly refers to steel moulds, this work was carried out on aluminium because of its advantages for machining and its suitability for moulds. In small batch production the manufacturers are interested in the production of aluminium moulds. A 5 axis CNC milling machine was used for the surface finishing of several parts, previously 3 axis machined, within equal cutting conditions. Different machining conditions on 3 and 5 axes finishing operations were tested. The comparison of the results allows to conclude that a better surface finish is achieved with 5 axis milling using an end mill inclined in the feed instead of the traditional 3 axis milling with a ball nose cutter. The application of the Design of Experiments technique together with multiple linear regression enables the establishment of a mathematical model of the process that gives the process parameter values that lead to the minimum machining time in order to achieve a certain roughness.
Journal of Production Engineering, 2017
The objective of this study is to identify optimum machining parameters on surface quality of sculptured parts. The effect of various machining process parameters such as machining strategy, feed, depth of cut and spindle speed on surface roughness during three-axis end milling of sculptured parts have been studied by performing a number of experiments constructed according to standard Taguchi's L9 orthogonal array design matrix. Grey relational analysis method was used to find the optimal machining process parameters and analysis of variance was carried out to find the significance and contribution of each machining parameter on performance characteristics. Finally, confirmation test was conducted to indicate the effectiveness of this proposed method.
Effective use of Cutting Parameters in Turning Process to Enhance Tool life
2017
Machining is the process of removing the excess material from the work piece or unwanted material from the work piece using a cutting tool. The surface finish and tool life obtain in machining process depends upon the various factors like work material, tool material , tool geometry, machine conditions, coolant and feed rate , speed , depth of cut etc. The focus of present study deals with finding optimal controlled process parameters to obtain good surface finish as well as here predicted tool life. It also shows the effect of the process parameters; cutting speed, feed rate and depth of cut on tool life. Experiments design and conducted based on Taguchi method and corresponding surface roughness were noted. The most affecting factor on tool life are cutting speed and feed observed after the experimentation. Here it is also concluded that tool life decreases with increases of cutting speed and feed in machining process for CNMG tool and grey cast iron work material combination.
CNC milling has become one of the most competent, productive and flexible manufacturing methods, for complicated or sculptured surfaces. With the rising demands of modern engineering products, the control of surface texture together with the cutting forces encountered has become more important. In this paper, the effects of various process parameters of CNC Milling like Spindle Speed (N), table feed rate (FR), depth of cut (DOC), step over (SO) and coolant pressure (CP) have been investigated to reveal their impact on surface roughness and cutting forces of hot die steel (H-11) using one variable at a time approach(OFAT). The experimental studies were performed on SURYA VF30 CNC VS machine. The processing of the job has been done by solid carbide four flute end-mill tools under finishing conditions. Prediction of surface roughness is very difficult using mathematical equations. The surface roughness (SR) increases with increase of table feed rate (FR), depth of cut (DOC), step over(SO) and decreases with increase in spindle speed(N) and coolant pressure(CP) & the cutting forces (CF) decreases with increase in spindle speed (N) and increases with table feed rate (FR) , depth of cut (DOC) and step over(SO).