Adaptive Toolpath for 3-Axis Milling of Thin Walled Parts

Grossi, Niccolò; Scippa, Antonio; Croppi, Lisa; Morelli, Lorenzo; Campatelli, Gianni

doi:10.17973/mmsj.2019_11_2019096

Cited by 11 publications

(12 citation statements)

References 8 publications

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“…Of the processes used in machining, those processes based on removing material from the workpiece by cutting have a special place. It can be seen that a large proportion of these processes are by cutting [ 1 , 2 , 3 , 4 , 5 , 6 , 7 ]. Essentially, machining is based on a strong compression of the workpiece material by the clearance surface of a cutting tool, until a shearing of the workpiece material occurs and material separates from the workpiece in the form of chips.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Thin Wall Milling Ability Using Disc Cutters

et al. 2023

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In some cases, industrial practice requires the production of walls or parts with a thickness of less than one millimeter from a metal workpiece. Such parts or walls can be made by milling using disc cutters. This machining method can lead to the generation of residual stresses that determine the appearance of a form deviation characterized by bending the part or the thin wall. To evaluate the suitability of a metallic material for the manufacturing of thin walls by milling with disc cutters, different factors capable of exerting influence on the deviation generated by the residual deformation of the walls were taken into account. A test sample and an experimental research program were designed for the purpose of obtaining an empirical mathematical model. The empirical mathematical model highlights the magnitude of the influence exerted by different input factors on the disc cutter milling process regarding the size of the deviation from the form, and the correct position of the wall or thin part, in the case of a test sample workpiece made of an aluminum alloy. Input factors considered were cutting speed, feed rate, cutter thickness, wall or part thickness, thin wall length, and height. To rank the input factors whose increase leads to an increase in shape deviation, the values of the exponents attached to the factors in question in the empirical mathematical model of the power-type function were taken into account. It was found that the values of the exponents are in the order 0.782 > 0.319 > 0.169 for wall height, feed rate, and wall width, respectively. It was thus established that the strongest influence on the residual deformation of the thin wall is exerted by its height.

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Section: Introductionmentioning

confidence: 99%

Evaluation of Thin Wall Milling Ability Using Disc Cutters

et al. 2023

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“…The method of error compensation during the milling operations of flexible thin-wall parts is presented by Ratchev et al [3] to reduce the deflection error of machined parts. To improve the accuracy of thin-walled machined parts, an adaptive toolpath methodology for three-axis milling is presented by Grossi et al [4]. The finite element method (FEM) based cutting velocity selection for thin-walled part machining is presented by Scippa et el.…”

Section: Introductionmentioning

confidence: 99%

Virtual Minimization of Residual Stress and Deflection Error in the Five-Axis Milling of Turbine Blades

Soori

Asmael

2021

SV-JME

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To simulate and analyse the real machined parts in virtual environments, virtual machining systems are applied to the production processes. Due to friction, chip forming, and the heat produced in the cutting zone, parts produced using machining operation have residual stress effects. The machining force and machining temperature can cause the deflection error in the machined turbine blades, which should be minimized to increase the accuracy of machined blades. To minimize the residual stress and deflection error of machined parts, optimized machining parameters can be obtained. In the present research work, the application of a virtual machining system is presented to predict and minimize the residual stress and deflection error in a five-axis milling operations of turbine blades. In order to predict the residual stress and deflection error in machined turbine blades, finite element analysis is implemented. Moreover, to minimize the residual stress and deflection error in machined turbine blades, optimized parameters of machining operations are obtained by using a genetic algorithm. To validate the research work, experimentally determining residual stress by using a X-ray diffraction method from the machined turbine blades is compared with the finite element results obtained from the virtual machining system. Also, in order to obtain the deflection error, the machined blades are measured by using the CMM machines. Thus, the accuracy and reliability of machined turbine blades can be increased by analysing and minimizing the residual stress and deflection error in virtual environments.

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“…In machining, the analysis of cutting forces is essential to increase both quality and productivity of the process [Liu 2002]. Indeed, the prediction of cutting forces is crucial to handle both static phenomena (i.e., static deflection [Nishida 2018;Grossi 2019]) and dynamic issues (i.e., vibrations [Budak 2003;Grossi 2017]). For 3-axis milling, many studies have been proposed concerning the prediction of cutting forces [Kapoor 1997;Matsumura 2017;Kiran 2019;Ducroux 2021].…”

Section: Introductionmentioning

confidence: 99%

Depths of Cut Identification in 3-Axis Milling Using Cutting Force Spectrum

Morelli¹,

Grossi²,

Scippa³

et al. 2021

MM SJ

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Cutting forces analysis is one of the most important means of improving machining quality and productivity. In 3-axis milling, the frequency domain analysis of the cutting forces provides information which can be adopted for both predicting and monitoring the cutting process. However, the evaluation of the cutting forces spectra requires the application of specific tools (i.e., Fourier’s Transform) to the time domain representation of the same cutting forces. This paper presents analytical formulations to directly evaluate the cutting force spectra starting from the tool geometry and the cutting parameters. The proposed formulations start from the expression of the cutting forces as a Fourier series and enhance the predictions showed in previous works by reducing the overall number of calculations needed. Then, the proposed formulations are applied to identify both radial and axial depths of cut exploiting the normalized cutting force spectrum. Finally, the proposed formulations and their application were numerically and experimentally validated. This work represents a preliminary step in the development of a monitoring system to identify cutting conditions in 3-axis milling.

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Adaptive Toolpath for 3-Axis Milling of Thin Walled Parts

Cited by 11 publications

References 8 publications

Evaluation of Thin Wall Milling Ability Using Disc Cutters

Evaluation of Thin Wall Milling Ability Using Disc Cutters

Virtual Minimization of Residual Stress and Deflection Error in the Five-Axis Milling of Turbine Blades

Depths of Cut Identification in 3-Axis Milling Using Cutting Force Spectrum

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