Evaluating the Roughness According to the Tool Path Strategy When Milling Free Form Surfaces for Mold Application

Souza, Adriano Fagali de; Machado, Adriane; Beckert, Sueli Fischer; Diniz, Anselmo Eduardo

doi:10.1016/j.procir.2014.03.089

Cited by 43 publications

(41 citation statements)

References 8 publications

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“…Due to different Ra parameters, a correction factor is introduced which modifies the feed rate in order to ensure better surface roughness. de Souza et al [9] present the influence of the tool path strategy on surface quality. The different strategies result in different machining time and surface quality, which has an influence on the polishing time of the surface.…”

Section: Introductionmentioning

confidence: 99%

A geometric approach of working tool diameter in 3-axis ball-end milling

Mikó

Zentay

2019

Int J Adv Manuf Technol

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When machining free-form surfaces with a ball-end milling tool, the working tool diameter is constantly changing even if the tool path is constant. The reason is that the surface normal of the milled surface is continuously changing along the milling path. When the working diameter is changing, the cutting parameters also change. This variation effects the roughness homogeneity of the smoothed surface. Simultaneous five-axis milling solves this problem; however, the price and complexity of this technology can be a problem for some industrial sectors. In the paper, the geometrical background of a solution to this problem is presented for a 3-axis ball-end milling process for machining a free form surface. The paper provides the deduction of the theory by the use of homogeneous transformations. The geometrical problem of the cutting process is treated locally where the general machined surface is substituted at every point by its tangent plane. From the result of the presented method, a milling strategy can be formulated for ball-end milling that minimises the change in the momentary working diameter thus providing a more constant cutting parameter.

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Section: Introductionmentioning

confidence: 99%

A geometric approach of working tool diameter in 3-axis ball-end milling

Mikó

Zentay

2019

Int J Adv Manuf Technol

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“…They found that it is possible to reduce machining time up to 37% with selection of proper optimization strategy without exceeding imposed machining parameter limits. In another study, Souza et al [9] investigated the effects of different tool path strategies on surface roughness and machining time during finish milling of a mold cavity. The results showed that when compared to the less appropriate option, selection of an improved tool path strategy can decrease the machining time and machining costs by 88% and 40%, respectively.…”

Section: Introductionmentioning

confidence: 99%

Improvement of Machining Processes: A Case Study

Gökçe¹,

Yeşilay²,

Uçak³

et al. 2019

acperpro

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In material removal processes, determination of optimal machining strategy is a key factor to increase productivity. This situation is gaining more importance when machining components with complex geometry. The current practice in the determination of machining strategy mostly depends on the experience of the machine operator. However, poorly designed machining processes lead to timeconsuming and costly solutions. Therefore, the improvement of machining processes plays a vital role in terms of machining costs. In this study, the machining process of a boom-body connector (GGG40) of a backhoe loader was improved. Improvements of toolpaths and cutting conditions of 22 different material removal processes were checked through a CAM software. According to the simulation results, the process plan was rearranged. Besides, some enhancements in casting model were conducted to decrease in the number of machining operations. When compared to current practice, a reduction of 55% in machining time was achieved.

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“…Also, Romero et al [12] compared the ZZ and CP strategy for three different pocket geometries (concave, and convex with and without islands). For complex geometries, Ramos, Relvas, and Simões [13] compared different strategies for finishing (ZZ, CP, and radial) using the same strategies for roughing in every case, while Fagili de Souza et al [14] studied four different finishing strategies (3-D offset, spiral, radial path, and ZZ) for mold applications. Schützer, Helleno, and Castellari [15] compared a ZZ strategy (45 • ) in finishing with a mix formed by four strategies adapted to the different regions of the geometry.…”

Section: Introductionmentioning

confidence: 99%

“…Schützer, Helleno, and Castellari [15] compared a ZZ strategy (45 • ) in finishing with a mix formed by four strategies adapted to the different regions of the geometry. Normally, the studies found in the literature are focused on finishing strategies and do not analyze the influence of roughing strategies on the surface roughness obtained on the complex surface [13][14][15][16].…”

Section: Introductionmentioning

confidence: 99%

Selection of Parameters and Strategies to Reduce Energy Consumption and Improve Surface Quality in EN-AW 7075 Molds Machining

Rodríguez‐Alabanda

Bonilla

Guerrero‐Vaca

et al. 2018

Metals

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The machining of cavities for blow molding is a long and costly process, with the objective of obtaining an excellent surface finish with the minimal possible electrical energy consumption (EEC). This work has studied which combination of cutting parameters and cutting strategies to use to achieve an optimum surface finish on the mold using the minimal associated EEC: in roughing operation, tool path strategy and axial depth of cut were studied; in finishing operation, tool path strategy, spindle-speed, feed-rate, and step-over were evaluated. Thirty-two molds were machined in blocks of aluminium alloy EN-AW 7075 T6 in a machining center of a three-axis, following an orthogonal design of experiments. The analysis of results demonstrates that: a roughing strategy has influence on the surface roughness on the bottom of the mold; a finishing strategy is an influential factor on the surface roughness on the walls of the mold; certain parameters have no relevance on the surface roughness but have an influence on the EEC; an adequate selection of cutting strategies and cutting parameters permit an improvement of surface roughness of up to 70%, and a reduction of 40% in EEC, compared to the less favorable tests.

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Evaluating the Roughness According to the Tool Path Strategy When Milling Free Form Surfaces for Mold Application

Cited by 43 publications

References 8 publications

A geometric approach of working tool diameter in 3-axis ball-end milling

A geometric approach of working tool diameter in 3-axis ball-end milling

Improvement of Machining Processes: A Case Study

Selection of Parameters and Strategies to Reduce Energy Consumption and Improve Surface Quality in EN-AW 7075 Molds Machining

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