Face Milling

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Placid Mathew Ferreira - One of the best experts on this subject based on the ideXlab platform.

  • an experimental investigation of rotary ultrasonic Face Milling
    International Journal of Machine Tools & Manufacture, 1999
    Co-Authors: Placid Mathew Ferreira
    Abstract:

    Reliable and cost-effective machining of advanced ceramics is crucially important for them to be widely used in a number of critical engineering applications. The potential of Rotary Ultrasonic Machining (RUM) process has been recognized as one of the reliable and cost-effective machining methods for advanced ceramics and commercial machinery is available for the process. One limitation of the commercial RUM machines is that only circular holes can be efficiently machined. An approach to extend the RUM process to Face Milling of ceramics was proposed and the development of the experimental apparatus as well as the preliminary experimental results were published earlier in this journal. As a follow-up, this paper will present the results of an experimental investigation of the newly-developed Rotary Ultrasonic Face Milling (RUFM) process. In this investigation, a five-variable two-level fractional factorial design is used to conduct the experiments. The purpose of these experiments is to reveal the main effects as well as the interaction effects of the process parameters on the process outputs such as Material Removal Rate (MRR), cutting force, material removal mode and surFace roughness.

H. Song - One of the best experts on this subject based on the ideXlab platform.

  • Modal Analysis of High-Speed Face Milling System Based on Composite Structure System Analysis Method
    Materials Science Forum, 2014
    Co-Authors: H. Song
    Abstract:

    This paper adopts composite structure system analysis method to perform modal analysis of high-speed Face Milling cutter which is mounted on the machine tool through FEM modal analysis. The key problem of this method is to obtain joint surFace parameters between the machine tool spindle and Face Milling cutter through experimental modal analysis and MATLAB software. The joint surFace parameters consist of linear stiffness, linear damping, rotation stiffness and rotation damping. After getting the frequency response function (FRF) at the tool tip of the Face Milling system through experimental modal analysis, the contact surFace parameters can be used to eliminate the influence of the machine tool to get modal parameters of the Face-Milling cutter itself. Based on the finite element model of Face Milling cutter, composite structure system analysis method can be used easily to acquire the dynamic performance of the Face Milling system through FEM modal analysis, greatly to improve the reliability of modal analysis, and is helpful to the dynamic design and the structure improvement of high speed Face Milling cutter.

  • Modal analysis of high-speed Face Milling system based on composite structure system analysis method
    Materials Science Forum, 2014
    Co-Authors: L.n. Liu, Z. Y. Shi, Z. Q. Liu, H. Song
    Abstract:

    This paper adopts composite structure system analysis method to perform modal analysis of high-speed Face Milling cutter which is mounted on the machine tool through FEM modal analysis. The key problem of this method is to obtain joint surFace parameters between the machine tool spindle and Face Milling cutter through experimental modal analysis and MATLAB software. The joint surFace parameters consist of linear stiffness, linear damping, rotation stiffness and rotation damping. After getting the frequency response function (FRF) at the tool tip of the Face Milling system through experimental modal analysis, the contact surFace parameters can be used to eliminate the influence of the machine tool to get modal parameters of the Face-Milling cutter itself. Based on the finite element model of Face Milling cutter, composite structure system analysis method can be used easily to acquire the dynamic performance of the Face Milling system through FEM modal analysis, greatly to improve the reliability of modal analysis, and is helpful to the dynamic design and the structure improvement of high speed Face Milling cutter. © (2014) Trans Tech Publications, Switzerland.

Chungshin Chang - One of the best experts on this subject based on the ideXlab platform.

  • a study of high efficiency Face Milling tools
    Journal of Materials Processing Technology, 2000
    Co-Authors: Chungshin Chang
    Abstract:

    Abstract A new predictive force model for a single-tooth Face Milling cutter with a chamfered main cutting edge has been derived. Machining tests has been conducted for fly cutting with a chamfered main cutting edge tools on plane surFaces. An S45C medium carbon plate has been used as the workpiece matrial. Force data from these tests were used to estimate the empirical constants of the mechanical model and to verify its prediction capabilities. The results show a good agreement between the predicted and measured forces. Since tool manufacturers does not provide tools with selected combinations of chamfered main cutting edge, radial angle, axial angle and inclination angles, tool holders manufactured in-house were used in the tests. The tips were prepared to the required geometry using a tool grinder.

Shiv Gopal Kapoor - One of the best experts on this subject based on the ideXlab platform.

  • Modeling and Prediction of Cutting Noise in the Face-Milling Process
    Journal of Manufacturing Science and Engineering-transactions of The Asme, 2007
    Co-Authors: Karthikeyan Sampath, Shiv Gopal Kapoor, Richard E. Devor
    Abstract:

    A cutting noise prediction model is developed to relate the cutter-workpiece vibrations to the sound pressure field around the cutter in the high-speed Face-Milling process. The cutter-workpiece vibration data are obtained from a dynamic mechanistic Face-Milling force simulation model. The total noise predicted, based on both cutting noise and aerodynamic noise prediction, compares well to the noise observed experimentally in the Face-Milling process. Using the model, the effects of various machining and cutter geometry parameters are studied. It is shown that cutter geometry, machine dynamics, and cutting speed all play important roles in determining overall noise in Face Milling.

  • modeling of cutting forces in a Face Milling operation with self propelled round insert Milling cutter
    International Journal of Machine Tools & Manufacture, 2005
    Co-Authors: Pradeep Kumar Baro, Suhas S Joshi, Shiv Gopal Kapoor
    Abstract:

    Abstract Rotary tools are being rediscovered for their applications in machining of ‘difficult-to-machine’ materials or for general improvement in the productivity of machining operations. While, a detailed analysis of application of rotary tools in turning operations has been done, their application in the generation of plain surFaces has received limited attention. This paper deals with the modeling of cutting forces in a Face-Milling operation performed using self-propelling inserts. The proposed model incorporates differences in the machining mechanics of self-propelling inserts due to the difference in their geometry and rotation in a static force prediction model in a Face-Milling operation with stationary inserts. The predicted values of cutting forces evaluated by the proposed model are in excellent agreement with the experimental value than those predicted using the static force model as it is.

  • Chatter Stability Analysis of the Variable Speed Face-Milling Process
    Journal of Manufacturing Science and Engineering-transactions of The Asme, 2000
    Co-Authors: Sridhar Sastry, Shiv Gopal Kapoor, Richard E. Devor, Geir E. Dullerud
    Abstract:

    In this study, a solution technique based on a discrete time approach is presented to the stability problem for the variable spindle speed Face-Milling process. The process dynamics are described by a set of differential-difference equations with time varying periodic coefficients and time delay. A finite difference scheme is used to discretize the system and model it as a linear time varying (LTV) system with multiple time delays. By considering all the states over one period of speed variation, the infinite dimensional periodic time-varying discrete system is converted to a finite dimensional time-varying discrete system. The eigenvalues of the state transition matrix of this finite dimensional system are then used to propose criteria for exponential stability. Predicted stability boundaries are compared with lobes generated by numerical time-domain simulations and experiments performed on an industrial grade variable speed Face-Milling testbed.

  • a model for the prediction of surFace flatness in Face Milling
    Journal of Manufacturing Science and Engineering-transactions of The Asme, 1997
    Co-Authors: F Gu, Shiv Gopal Kapoor, Shreyes N Melkote, Richard E. Devor
    Abstract:

    This paper presents a new model for the prediction of surFace flatness errors in Face Milling. The model includes the effects of machining conditions, elastic deformation of the cutter-spindle and workpiece-fixture assemblies, static spindle axis tilt and axially inclined tool path. A new method called equivalent flexibility influence coefficient method is used to compute the elastic deflection of the cutter-spindle and workpiece-fixture assembly at the points of cutting force application. Single insert and multi-insert Face Milling experiments are conducted to evaluate the predictive ability of the surFace flatness model. A comparison of the model predictions and measurements shows good agreement. The influence of static spindle axis tilt on the surFace flatness error is found to be very significant. It is shown that care needs to be exercised in comparing the model predictions based on elastic deflection of the machining system and spindle axis tilt with the surFace flatness error measurements due to the fact that these measurements may be inflated by inclusion of the surFace roughness.

  • the effects of variable speed cutting on vibration control in Face Milling
    Journal of Engineering for Industry, 1990
    Co-Authors: Richard E. Devor, Shiv Gopal Kapoor
    Abstract:

    This paper discusses the use of variable speed cutting for vibration control in the Face Milling process. Both simulation and experimental results show that the self-excited vibrations that can occur during constant speed cutting, and hence put limitation on the possible size of cut, can be suppressed by continuously varying the spindle speed. Through both analytical and experimental studies, the shape of variable speed trajectory has been examined, in terms of both the trackability by the spindle servo system and performance in terms of vibration suppression. It was found that a sinusoidal wave because of its acceleration and jerk characteristics can be tracked more precisely than some other periodic waves. The dynamic Face Milling force model was used to study the effects of speed trajectory parameters, namely, the frequency and amplitude. The results, in general, show the method to be fairly robust to the specific nature of the machining situation in terms of both processing conditions and system dynamics. Speed trajectory design was, however, shown to be somewhat dependent upon the nominal cutting speed and dominant frequencies of the system.

X. Ai - One of the best experts on this subject based on the ideXlab platform.

  • Spectra analysis of Face Milling cutter aeroacoustic noise
    Jixie Gongcheng Xuebao Journal of Mechanical Engineering, 2011
    Co-Authors: Z. Liu, Lijun Liu, C. Ji, X. Ai
    Abstract:

    The noise produced by high speed Face Milling is detrimental to the machine operators. The major source of aeroacoustic noise is primarily dipole in nature. A noise prediction model based on Ffowcs Williams-Hawkings equation is used to predict aeroacoustic noise in Face Milling cutters. Numerical simulation of air flow in the Milling cutter system is performed by using CFD method. The predicted sound pressure level based on mathematical model is 4.0 dB lower than measurement results at 9000 rpm. And the error is about 7%. The chip flute region and insert rake Face are found to be important factors in determining aeroacoustic noise in rotating Face Milling cutter. The directivity of aeroacoustic noise is verified in the axial direction. The broadband noise spreads over a broad range of frequencies and contributes significantly to overall noise, but the discrete noise at the rotational frequency is significantly higher. It can provide theory for low noise design and prediction of high speed Face Milling cutter. © 2011 Journal of Mechanical Engineering.