End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies

Zahid, Muhammed Nafis Osman; Case, Keith; Watts, Darren M.

doi:10.1080/21693277.2015.1094756

Cited by 8 publications

(2 citation statements)

References 20 publications

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“…In 2015, Osman Zahid et al found out that the capability of CNC for the rapid machining operation can be improved by using dissimilar end mill tools for finishing. They introduced a new layer removal methodology in which an indexing device is used to clamp the workpiece and an SSF to hold the part during rapid machining [16].…”

Section: Literature Reviewmentioning

confidence: 99%

Sacrificial Support Fixture Optimisation for the CNC Rapid Machining of Medical Parts with Thin Ends

Ramteke

Ashtankar

2019

TFAMENA

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The purpose of this paper is to develop a methodology for optimising the shape of automated sacrificial support fixture (SSF) design, so as to machine a part with thin ends (like the hip joint) using a rapid machining process. A sacrificial support fixture is created at the ends of the part to give support to the part during machining. Finite element analysis (FEA) is used to optimise the shape of sacrificial support fixture for the machining of a part via computer numerical control rapid prototyping (CNC-RP). The research work proves that the optimised design of a sacrificial support fixture has been extremely flexible in securing a variety of intricate parts having thin ends in the computer numerical control rapid prototyping machining. For rapid machining, a tapered support is best suited for the part with thin ends. The limitation of the optimised sacrificial support fixture, designed for an intricate part, is that it is applicable only to CNC machining with the four axis rotational setup.

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Section: Literature Reviewmentioning

confidence: 99%

Sacrificial Support Fixture Optimisation for the CNC Rapid Machining of Medical Parts with Thin Ends

Ramteke

Ashtankar

2019

TFAMENA

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“…The use of additive techniques enables the production of objects with complex and irregular shapes, which is very often impossible in the case of other technologies. However, due to the high level of integration of computer systems into production processes in the era of Industry 4.0 [ 9 ], the term rapid prototyping and tooling should be considered as a broader concept, because its components are often directly or indirectly related to other forms of production, such as computer numerical control (CNC) machining (through the integration of CAD/CAM environments) [ 10 ], reverse engineering (3D scanning) [ 11 ] or investment casting (making disposable casting patterns) [ 12 , 13 ].…”

Section: Introductionmentioning

confidence: 99%

Heat Transfer Analysis of 3D Printed Wax Injection Mold Used in Investment Casting

et al. 2022

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Investment casting is one of the precise casting methods where disposable wax patterns made in wax injection molds are used to make a casting mold. The production capacity of precision foundry is determined by the time taken for producing wax patterns, which depends on the time taken for wax solidification. Wax injection molds are usually made of aluminum or copper alloys with the use of expensive and time-consuming computer numerical control (CNC) processing, which makes low-volume production unprofitable. To reduce these costs, the authors present a heat transfer analysis of a 3D printed wax injection mold. Due to the low thermal conductivity of the photopolymer resin, the influence of different cooling channels’ shapes was investigated to improve the time of the manufacturing process. Transient thermal analysis was performed using COMSOL software based on the finite element method (FEM) and included a simulation of wax injection mold cooling with cold air (−23 °C), water, and without cooling. The analysis showed that use of cooling channels in the case of photopolymer material significantly reduces the solidification time of the sample (about 10 s shorter), and that under certain conditions, it is possible to obtain better cooling than obtained with the aluminum reference wax injection mold (after approximately 25–30 s). This approach allows to reduce the production costs of low-volume castings.

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3D printing for ultra-precision machining: current status, opportunities, and future perspectives

He,

Yip,

Yan

et al. 2024

Front. Mech. Eng.

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Additive manufacturing, particularly 3D printing, has revolutionized the manufacturing industry by allowing the production of complex and intricate parts at a lower cost and with greater efficiency. However, 3D-printed parts frequently require post-processing or integration with other machining technologies to achieve the desired surface finish, accuracy, and mechanical properties. Ultra-precision machining (UPM) is a potential machining technology that addresses these challenges by enabling high surface quality, accuracy, and repeatability in 3D-printed components. This study provides an overview of the current state of UPM for 3D printing, including the current UPM and 3D printing stages, and the application of UPM to 3D printing. Following the presentation of current stage perspectives, this study presents a detailed discussion of the benefits of combining UPM with 3D printing and the opportunities for leveraging UPM on 3D printing or supporting each other. In particular, future opportunities focus on cutting tools manufactured via 3D printing for UPM, UPM of 3D-printed components for real-world applications, and post-machining of 3D-printed components. Finally, future prospects for integrating the two advanced manufacturing technologies into potential industries are discussed. This study concludes that UPM is a promising technology for 3D-printed components, exhibiting the potential to improve the functionality and performance of 3D-printed products in various applications. It also discusses how UPM and 3D printing can complement each other.

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End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies

Cited by 8 publications

References 20 publications

Sacrificial Support Fixture Optimisation for the CNC Rapid Machining of Medical Parts with Thin Ends

Sacrificial Support Fixture Optimisation for the CNC Rapid Machining of Medical Parts with Thin Ends

Heat Transfer Analysis of 3D Printed Wax Injection Mold Used in Investment Casting

3D printing for ultra-precision machining: current status, opportunities, and future perspectives

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