The article deals with comparison and evaluation of the milling strategies that are available in CAM systems and are used to produce components with freeform surfaces. For the purpose of the experiment, sample with freeform features was designed to employ different milling strategies when 3 axis machining. Evaluation of the milling strategies was carried out by surface roughness measurement, comparison of the actual machining time with a simulation time as well as visual control of the sample surface with a surface obtained in simulation. Acquired research results can be utilized within production process of tools with sculptured surfaces, such as tools for metal sheet forming, dies, molds for plastics and many others.
The current mechanical engineering is inconceivable without the implementation of CAx systems in design and manufacturing process of individual components. The automotive industry is a clear evidence of how CAx systems affect the innovation cycle of its product -a car. The innovation cycle in automotive was reduced from 8-12 years to the current 4-6 years. Even in this short interval automakers make some small design modifications called a facelift. Development in the automotive industry, therefore, is closely related to news and functionality CAx systems. CAD systems at the turn of the millennium are characterized as parametric graphic systems with a history tree of product creation. Parametric design implemented into CAD systems makes the model variable and open to rapid change management. The history tree in turn enables rapid editing and modification of forming or editing functions.
The paper deals with selection and evaluation of milling strategies, available in CAM systems and applicable when complicated shape parts are produced, such as forming dies. A method to obtain samples is proposed and this stems from real forming die surface machined by proper strategies. The strategy applicability for the whole part -forming die -is reviewed by the particular specimen evaluation. The presented methodology has been verified by machining model die and comparing it to the production procedure proposed in other CAM systems.
The paper deals with the effects of CAM data needed to produce desired quality of shaped surfaces in forming dies making. In general, the input CAM data have strong influence to the final surface quality. The shaped surfaces 3D milling has been modeled as end ball milling of the surfaces with defined inclination. The end ball milling is the most common way to finish shaped surfaces. Directions of the milling tools motion and applied cutting conditions have been used to simulate data when setting milling strategies. The resultant machined surface quality has been identified in terms of the surface roughness. The paper introduces recommendations applicable to the programming of the different types of milling strategy when producing form surfaces.
Freeform surfaces are present on an increasing number of engineering products. Three- and multi-axis computer numerical control milling machines are commonly used for improved production. Computer-aided manufacturing (CAM) systems are used almost exclusively for the creation of programs for a variety of machining centers. This study compared the quality of freeform surfaces made by 3- and 5-axis milling using three commonly used strategies (linear, offset, and spiral). The CAM system-predicted surfaces were also compared with the actual surfaces. A test sample with a freeform surface was used for the experiments. Considering the size and distribution, the discrepancy between the predicted surface deviations and the deviations in the produced samples was proven. Maximum negative surface deviations, when 5-axis milling, employed linear and spiral strategy of 29% and 71% less than those produced by the 3-axis milling. On the contrary, positive deviations were 48% smaller. A comparison of the scans showed that the two strategies (linear and spiral) yielded better results for 5-axis milling, and the offset strategy was better for 3-axis milling. Evaluation of the achieved surface roughness showed that the milling method did not significantly affect the surface quality in the linear strategy. However, other two strategies (offset and spiral) achieved better results with 5-axis milling compared to 3-axis milling. The proposed method of evaluating the accuracy of machined free form surfaces can be used in experimental as well as production activities.
Titanium alloy Ti6Al4V represents one of the most frequently used alloys in medical as well as in aerospace industry and is considered as a difficult to cut material. In this paper, cutting experiments within throughput drilling were carried out under the varying cutting speed, feed and tool geometry (cutting edge radius and clearance angle). The effects of cutting speed feed and tool geometry on thrust force in drilling Ti6Al4V alloy were investigated applying design of experiment (DoE) according to Taguchi plan L16. The effect of above mentioned parameters was investigated through analysis of the S/N ratios (smaller is better) and ANOVA analysis. All analyses were performed using statistical software Minitab and Matlab. In the case of thrust force, the feed is the main influencing factor, followed by cutting speed, cutting edge radius and clearance angle.
The article deals with the comparison and evaluation of milling strategies, which are available in CAM systems and are used for the production of components with freeform surfaces. For the purpose of the experiment a test sample with a repeating shape feature was designed. First half of the test sample shape features were machined using 3-Axis milling strategies while second half was performed with strategies available on 5-Axis CNC machining centre. Simulated machining times as well as virtually machined surfaces using color maps with deviation values were evaluated by employed CAM software. Obtained data was used to evaluate the performance of 3-Axis and 5-Axis milling centre both individually and mutually. These results will be used to compare software data with data obtained from real sample production. The main goal is to verify the reliability of the results provided by CAM systems in the production of parts with freeform feature surfaces.
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