A discrete simulation-based algorithm for the technological investigation of 2.5D milling operations

Jacsó, Ádám; Szalay, Tibor; Jáuregui-Correa, Juan Carlos; Rodríguez‐Reséndiz, Juvenal

doi:10.1177/0954406218757267

Cited by 13 publications

(8 citation statements)

References 49 publications

(49 reference statements)

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“…9. When designing the movement path (toolpath) for cutting force-optimised milling of quasi-homogeneous materials, the chip cross-section should be optimised primarily [51,52]. In the case of UD-CFRP composite, due to the anisotropy, the direction of the reinforcing fibres also significantly influences the milling tool paths optimised for the force minimum, so it is advisable to take this into account when milling UD-CFRP.…”

Section: Comparison and Discussionmentioning

confidence: 99%

Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

Geier

2020

Int J Adv Manuf Technol

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Machining of carbon fibre reinforced polymer (CFRP) composites is extremely difficult, mainly due to their inhomogeneous and anisotropic properties. Predicting of cutting force during machining of CFRP is also difficult because the machinability properties of the composite are significantly orientation-dependent (fibre and machining directions). The main objective of the present study is to analyse the influence of fibre orientation on cutting force in milling of unidirectional CFRP. Up and down milling experiences were conducted based on a full factorial design. Experimental data were processed by fast Fourier transformation, regression analysis, and graphical adequate analysis. Multiple-order polynomial models were developed in order to minimise cutting force. Experimental results show that fibre orientation angle significantly influences the cutting force; furthermore, it does not have a significant effect on the passive force component, while the radial force component is more sensitive to the fibre orientation at up milling, than at down milling. An optimal condition is recommended for zig-zag milling of unidirectional CFRPs.

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Section: Comparison and Discussionmentioning

confidence: 99%

Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

Geier

2020

Int J Adv Manuf Technol

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“…A new application introduced by [5] provides simulation algorithm that is capable of producing all the necessary geometric information about the machining process.…”

Section: Literature Reviewmentioning

confidence: 99%

Performance Improvement using Simulation Tool in a Tiles Production Facility

Nadir

Habib

Khattak

et al. 2020

Mehran Univ. res. j. eng. technol.

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In recent times, the globalization of markets due to the improvement of utilization of resources has significant impact on the manufacturing systems. International competition forced companies to establish efficient and effective production facilities that provide best possible outcome in terms of profitability, throughput and lead time. In this background, every industrial facility is in competition to remain competitive in the market and be flexible for future changes. It is not easy to change the environment of any facility in order to check the results beforehand therefore simulation is a viable option. Simulation tools are used to help analyze performance measures for improvement. This paper presents a case by analyzing a facility in order to improve its production using simulation tool. In this study, simulation model for the production facility of Fort Ceramic Company is developed from its current state and then changes are made to its inter-arrival time. Models for both improved and current systems are developed in the simulation tool. Data analyzed in the simulation tool shows better results that represent a significant improvement in productivity, cycle time and throughput time to optimize the system.It is also observed that by decreasing the inter arrival time there is increase in the throughput which improves the revenue.

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“…The test was conducted using Wolfram Mathematica version 11 numerical equation solver functions, which enabled the measurement of the necessary CPU time (the CPU type used in the scope of the experiment was Intel Core i3-3220 3.30 GHz). For checking the engagement, a self-developed discrete model-based simulator has been used [13]. The results can be seen in Fig.…”

Section: Accuracy and Computational Costmentioning

confidence: 99%

“…The common point of the above-mentioned solutions is that they are all based on geometry, which means that they concentrate only on removing the machining allowance. Thus, their common deficiency is that they do not take into consideration the pertaining technological criteria [12]; therefore, the tool load during cutting may heavily fluctuate [13].…”

Section: Introductionmentioning

confidence: 99%

The fast constant engagement offsetting method for generating milling tool paths

Jacsó

Mátyási

Szalay

2019

Int J Adv Manuf Technol

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It is a well-established fact that when equidistant tool paths are used for 2.5D milling operations tool load varies based on the functions of path curvature. This phenomenon makes the optimal selection of cutting parameters more difficult, and the local load peaks are also detrimental to machining stability and tool life. Numerous publications address possible solutions to eliminate the problems caused by varied cutting parameters. The best solution for this is to keep the cutter engagement at a constant value. Nowadays, several methods are available to generate tool paths which are able to maintain constant cutter engagement, but the widespread use of such solutions is significantly hindered, because in this scenario complex calculations are required. This article offers a solution to this problem by presenting a new non-equidistant offsetting method for ensuring a constant cutter engagement angle. The algorithm developed for this purpose is based on simple geometrical equations and allows for its widespread use just like pixel-based methods. Concerning this new solution, computation needs and uniform tool load are verified by simulation and through experiments. The experiments have shown favourable results. Keywords Tool path generation. Cutter engagement. High-speed milling. Cutting force. Non-equidistant offsetting Nomenclature a e Effective radial immersion [mm] a p Axial depth of cut [mm] c(t) Parametric representation of workpiece contour [{mm, mm}] f z Feed per tooth [mm] h ex Maximum chip thickness [mm] i, j Step index [−] n Spindle speed [1/min] p(t) Parametric representation of tool path [{mm, mm}] r tool Tool radius [mm] s Stepover [mm] t Free parameter of curve equations [−] v Feed vector [{mm, mm}] v c Cutting speed [m/min] v f Feed rate [mm/min] w Trochoidal step [mm] z Number of teeth [−] C Entry point of the cutting edge [{mm, mm}] D tool Tool diameter [mm] MRR Material removal rate [mm 3 /min] P Tool path point [{mm, mm}] Q Exit point of cutting edge [{mm, mm}] V(x, y) Vector field [{mm, mm}, {mm, mm}] a, β Angle parameters [ ∘ ] Δs Stepsize[−] θ Cutter engagement angle [ ∘ ]

show abstract

A discrete simulation-based algorithm for the technological investigation of 2.5D milling operations

Cited by 13 publications

References 49 publications

Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

Performance Improvement using Simulation Tool in a Tiles Production Facility

The fast constant engagement offsetting method for generating milling tool paths

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