The Experts below are selected from a list of 12801 Experts worldwide ranked by ideXlab platform
Paul Xirouchakis - One of the best experts on this subject based on the ideXlab platform.
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fem based prediction of workpiece transient temperature distribution and deformations during milling
The International Journal of Advanced Manufacturing Technology, 2009Co-Authors: Paul XirouchakisAbstract:In high-speed dry milling of thin-walled parts, the cutter-workpiece temperature rises asymptotically with cutting speed, causing excessive cutter tooth wear and workpiece thermal expansion, which in turn reduces the cutter life and produces dimensional and geometrical variabilities in the machined part. Therefore, a basic understanding of the thermal aspect of Machining and the effecting parameters is essential for achieving better part quality with improved productivity. This paper presents a transient milling Simulation model to assist manufacturing engineers in gaining in-depth understanding of the thermomechanical aspects of Machining and their influence on resulted part quality. Based on the finite-element method approach, the model can predict transient temperature distributions and resulted elastic-plastic deformations induced during the milling of 2.5D prismatic parts comprising features like slots, steps, pockets, etc. The advantages of the proposed model over previous works are that it (1) performs feature-based Machining Simulation considering transient thermomechanical loading conditions; (2) allows modeling the effects of coolant on convective heat transfer rate; and (3) considers the nonlinear behavior of the workpiece due to its changing geometry, inelastic material properties, and flexible fixture–workpiece contacts. The prediction accuracy of the model was validated with experimental results obtained during the course of the research work. A good agreement between the numerical and experimental results was found for different test cases with varying part geometries and Machining conditions.
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finite element method based Machining Simulation environment for analyzing part errors induced during milling of thin walled components
International Journal of Machine Tools & Manufacture, 2008Co-Authors: Jitender K Rai, Paul XirouchakisAbstract:The rigid body motion of the workpieces and their elastic-plastic deformations induced during high speed milling of thin-walled parts are the main root causes of part geometrical and dimensional variabilities; these are governed mainly from the choice of process plan parameters such as fixture layout design, operation sequence, selected tool path strategies and the values of cutting variables. Therefore, it becomes necessary to judge the validity of a given process plan before going into actual Machining. This paper presents an overview of a comprehensive finite element method (FEM) based milling process plan verification model and associated tools, which by considering the effects of fixturing, operation sequence, tool path and cutting parameters simulates the milling process in a transient 3D virtual environment and predicts the part thin wall deflections and elastic-plastic deformations during Machining. The advantages of the proposed model over previous works are: (i) Performs a computationally efficient transient thermo-mechanical coupled field milling Simulation of complex prismatic parts comprising any combination of Machining features like steps, slots, pockets, nested features, etc., using a feature based milling Simulation approach; (ii) Predicts the workpiece non-linear behavior during Machining due to its changing geometry, inelastic material properties and fixture-workpiece flexible contacts; (iii) Allows the modelling of the effects of initial residual stresses (residing inside the raw stock) on part deformations; (iv) Incorporates an integrated analytical Machining load (cutting force components and average shear plane temperature) model; and (v) Provides a seamless interface to import an automatic programming tool file (APT file) generated by CAM packages like CATIA V5. The prediction accuracy of the model was validated experimentally and the obtained numerical and experimental results were found in good agreement. (C) 2007 Elsevier Ltd. All rights reserved.
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finite element method based Machining Simulation environment for analyzing part errors induced during milling of thin walled components
International Journal of Machine Tools & Manufacture, 2008Co-Authors: Paul XirouchakisAbstract:The rigid body motion of the workpieces and their elastic-plastic deformations induced during high speed milling of thin-walled parts are the main root causes of part geometrical and dimensional variabilities; these are governed mainly from the choice of process plan parameters such as fixture layout design, operation sequence, selected tool path strategies and the values of cutting variables. Therefore, it becomes necessary to judge the validity of a given process plan before going into actual Machining. This paper presents an overview of a comprehensive finite element method (FEM) based milling process plan verification model and associated tools, which by considering the effects of fixturing, operation sequence, tool path and cutting parameters simulates the milling process in a transient 3D virtual environment and predicts the part thin wall deflections and elastic-plastic deformations during Machining. The advantages of the proposed model over previous works are: (i) Performs a computationally efficient transient thermo-mechanical coupled field milling Simulation of complex prismatic parts comprising any combination of Machining features like steps, slots, pockets, nested features, etc., using a feature based milling Simulation approach; (ii) Predicts the workpiece non-linear behavior during Machining due to its changing geometry, inelastic material properties and fixture-workpiece flexible contacts; (iii) Allows the modelling of the effects of initial residual stresses (residing inside the raw stock) on part deformations; (iv) Incorporates an integrated analytical Machining load (cutting force components and average shear plane temperature) model; and (v) Provides a seamless interface to import an automatic programming tool file (APT file) generated by CAM packages like CATIA V5. The prediction accuracy of the model was validated experimentally and the obtained numerical and experimental results were found in good agreement. (C) 2007 Elsevier Ltd. All rights reserved.
Kai Tang - One of the best experts on this subject based on the ideXlab platform.
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optimization of Machining strip width using effective cutting shape of flat end cutter for five axis free form surface Machining
The International Journal of Advanced Manufacturing Technology, 2018Co-Authors: Baohai Wu, Mancang Liang, Ying Zhang, Kai TangAbstract:Tool postures of the flat-end cutter can make a huge difference to both Machining strip width and Machining efficiency in five-axis end milling. Most of current methods evaluate the Machining strip width and implement a tool orientation optimization by finding two intersection points between the effective cutting profile of a flat-end cutter and the offset surface profile which represents machined surface. However, real Machining strip width and real residual height should be formed between two adjacent cutter contours. As the results, two problems of current methods cannot be avoided: (1) Machining strip width computed on a single cutter location cannot accurately represent the distance between two adjacent tool paths and (2) excessive overlap or larger span length between two adjacent cutter contours leads to unsteady residual height, which causes surface quality differences. In order to solve the above problems, a more suitable method for computing Machining strip width is presented and proved in this paper. A flat-end cutter is adopted and the analytical model of effective cutting shape for this kind of tool is constructed firstly. Later, a geometric foundation to achieve optimization is established by investigating the impact of different flat-end cutter postures on the Machining strip width. Furthermore, the reasonable strip width is obtained and optimized by implementing an iterative and optimization approach under the given scallop height. A three-dimensional centrifugal compressor blade is used as a numerical example to verify the approach presented in this paper. To prove the superiority of the involved method, the research gives a comparison with UG method with the same cutting parameters. Numerical experiment suggests that Machining efficiency of the paper’s method improves by 37.85%. Finally, a Machining Simulation is performed in the VERICUT software to testify that a uniform error distribution is created.
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optimization of Machining strip width using effective cutting shape of flat end cutter for five axis free form surface Machining
The International Journal of Advanced Manufacturing Technology, 2018Co-Authors: Baohai Wu, Mancang Liang, Ying Zhang, Kai TangAbstract:Tool postures of the flat-end cutter can make a huge difference to both Machining strip width and Machining efficiency in five-axis end milling. Most of current methods evaluate the Machining strip width and implement a tool orientation optimization by finding two intersection points between the effective cutting profile of a flat-end cutter and the offset surface profile which represents machined surface. However, real Machining strip width and real residual height should be formed between two adjacent cutter contours. As the results, two problems of current methods cannot be avoided: (1) Machining strip width computed on a single cutter location cannot accurately represent the distance between two adjacent tool paths and (2) excessive overlap or larger span length between two adjacent cutter contours leads to unsteady residual height, which causes surface quality differences. In order to solve the above problems, a more suitable method for computing Machining strip width is presented and proved in this paper. A flat-end cutter is adopted and the analytical model of effective cutting shape for this kind of tool is constructed firstly. Later, a geometric foundation to achieve optimization is established by investigating the impact of different flat-end cutter postures on the Machining strip width. Furthermore, the reasonable strip width is obtained and optimized by implementing an iterative and optimization approach under the given scallop height. A three-dimensional centrifugal compressor blade is used as a numerical example to verify the approach presented in this paper. To prove the superiority of the involved method, the research gives a comparison with UG method with the same cutting parameters. Numerical experiment suggests that Machining efficiency of the paper’s method improves by 37.85%. Finally, a Machining Simulation is performed in the VERICUT software to testify that a uniform error distribution is created.
Jitender K Rai - One of the best experts on this subject based on the ideXlab platform.
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finite element method based Machining Simulation environment for analyzing part errors induced during milling of thin walled components
International Journal of Machine Tools & Manufacture, 2008Co-Authors: Jitender K Rai, Paul XirouchakisAbstract:The rigid body motion of the workpieces and their elastic-plastic deformations induced during high speed milling of thin-walled parts are the main root causes of part geometrical and dimensional variabilities; these are governed mainly from the choice of process plan parameters such as fixture layout design, operation sequence, selected tool path strategies and the values of cutting variables. Therefore, it becomes necessary to judge the validity of a given process plan before going into actual Machining. This paper presents an overview of a comprehensive finite element method (FEM) based milling process plan verification model and associated tools, which by considering the effects of fixturing, operation sequence, tool path and cutting parameters simulates the milling process in a transient 3D virtual environment and predicts the part thin wall deflections and elastic-plastic deformations during Machining. The advantages of the proposed model over previous works are: (i) Performs a computationally efficient transient thermo-mechanical coupled field milling Simulation of complex prismatic parts comprising any combination of Machining features like steps, slots, pockets, nested features, etc., using a feature based milling Simulation approach; (ii) Predicts the workpiece non-linear behavior during Machining due to its changing geometry, inelastic material properties and fixture-workpiece flexible contacts; (iii) Allows the modelling of the effects of initial residual stresses (residing inside the raw stock) on part deformations; (iv) Incorporates an integrated analytical Machining load (cutting force components and average shear plane temperature) model; and (v) Provides a seamless interface to import an automatic programming tool file (APT file) generated by CAM packages like CATIA V5. The prediction accuracy of the model was validated experimentally and the obtained numerical and experimental results were found in good agreement. (C) 2007 Elsevier Ltd. All rights reserved.
Han Ding - One of the best experts on this subject based on the ideXlab platform.
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formulating the swept envelope of rotary cutter undergoing general spatial motion for multi axis nc Machining
International Journal of Machine Tools & Manufacture, 2009Co-Authors: Limin Zhu, Gang Zheng, Han DingAbstract:Abstract Based on the tangency condition in envelope theory and the body velocity representation in spatial kinematics, a closed-form solution of the swept envelope of a general rotary cutter moving along a general tool path defined in the NC programs is derived. No additional moving frames or local frames are required, and the computational formulas are independent of the types of the machines. The results can be applied to NC Machining Simulation, tool path optimization, and CAD/CAM of spatial cams.
Baohai Wu - One of the best experts on this subject based on the ideXlab platform.
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optimization of Machining strip width using effective cutting shape of flat end cutter for five axis free form surface Machining
The International Journal of Advanced Manufacturing Technology, 2018Co-Authors: Baohai Wu, Mancang Liang, Ying Zhang, Kai TangAbstract:Tool postures of the flat-end cutter can make a huge difference to both Machining strip width and Machining efficiency in five-axis end milling. Most of current methods evaluate the Machining strip width and implement a tool orientation optimization by finding two intersection points between the effective cutting profile of a flat-end cutter and the offset surface profile which represents machined surface. However, real Machining strip width and real residual height should be formed between two adjacent cutter contours. As the results, two problems of current methods cannot be avoided: (1) Machining strip width computed on a single cutter location cannot accurately represent the distance between two adjacent tool paths and (2) excessive overlap or larger span length between two adjacent cutter contours leads to unsteady residual height, which causes surface quality differences. In order to solve the above problems, a more suitable method for computing Machining strip width is presented and proved in this paper. A flat-end cutter is adopted and the analytical model of effective cutting shape for this kind of tool is constructed firstly. Later, a geometric foundation to achieve optimization is established by investigating the impact of different flat-end cutter postures on the Machining strip width. Furthermore, the reasonable strip width is obtained and optimized by implementing an iterative and optimization approach under the given scallop height. A three-dimensional centrifugal compressor blade is used as a numerical example to verify the approach presented in this paper. To prove the superiority of the involved method, the research gives a comparison with UG method with the same cutting parameters. Numerical experiment suggests that Machining efficiency of the paper’s method improves by 37.85%. Finally, a Machining Simulation is performed in the VERICUT software to testify that a uniform error distribution is created.
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optimization of Machining strip width using effective cutting shape of flat end cutter for five axis free form surface Machining
The International Journal of Advanced Manufacturing Technology, 2018Co-Authors: Baohai Wu, Mancang Liang, Ying Zhang, Kai TangAbstract:Tool postures of the flat-end cutter can make a huge difference to both Machining strip width and Machining efficiency in five-axis end milling. Most of current methods evaluate the Machining strip width and implement a tool orientation optimization by finding two intersection points between the effective cutting profile of a flat-end cutter and the offset surface profile which represents machined surface. However, real Machining strip width and real residual height should be formed between two adjacent cutter contours. As the results, two problems of current methods cannot be avoided: (1) Machining strip width computed on a single cutter location cannot accurately represent the distance between two adjacent tool paths and (2) excessive overlap or larger span length between two adjacent cutter contours leads to unsteady residual height, which causes surface quality differences. In order to solve the above problems, a more suitable method for computing Machining strip width is presented and proved in this paper. A flat-end cutter is adopted and the analytical model of effective cutting shape for this kind of tool is constructed firstly. Later, a geometric foundation to achieve optimization is established by investigating the impact of different flat-end cutter postures on the Machining strip width. Furthermore, the reasonable strip width is obtained and optimized by implementing an iterative and optimization approach under the given scallop height. A three-dimensional centrifugal compressor blade is used as a numerical example to verify the approach presented in this paper. To prove the superiority of the involved method, the research gives a comparison with UG method with the same cutting parameters. Numerical experiment suggests that Machining efficiency of the paper’s method improves by 37.85%. Finally, a Machining Simulation is performed in the VERICUT software to testify that a uniform error distribution is created.
