Modeling and Prediction of Cutting Noise in the Face-Milling Process

Sampath, Karthikeyan; Kapoor, Shiv Gopal; DeVor, Richard E.

doi:10.1115/1.2716702

Cited by 11 publications

(6 citation statements)

References 2 publications

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“…Moreover, the method is also applicable to the analysis and calculation of milling cutter aerodynamic noise under high-speed rotation. Sampath et al [ 78 ] developed a cutting noise prediction model that relates cutter–workpiece vibrations to the sound pressure field around the cutter during a high-speed face-milling process. Moreover, they used the model to analyze the effects of various cutting parameters and tool geometric parameters on noise.…”

Section: Noise Signal Acquisition and Numerical Analysis And Noise Co...mentioning

confidence: 99%

“…A high noise level can lead to operator discomfort, increased stress, communication problems, and workshop safety problems, and thus, it affects production efficiency. Therefore, predicting and controlling the noise level generated during machining is crucial [ 78 ]. The effect of noise on the machining process is primarily reflected in two aspects.…”

Section: Noise Signal Acquisition and Numerical Analysis And Noise Co...mentioning

confidence: 99%

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Research Progress of Noise in High-Speed Cutting Machining

Wei

Shang

Peng

et al. 2022

Sensors

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High-speed cutting technology has become a development trend in the material processing industry. However, high-intensity noise generated during high-speed cutting exerts a potential effect on the processing efficiency, processing accuracy, and product quality of the workpiece; it may even cause hidden safety hazards. To conduct an in-depth study of noise in high-speed cutting machining, this work reviews noise sources, noise collection and numerical recognition, noise control, and condition monitoring based on acoustic signals. First, this article introduces noise sources, noise signal acquisition equipment, and analysis software. It is pointed out that how to accurately classify and recognize the target signal in the complex high-speed machining environment is one of the focuses of scholars’ research. Then, it points out that a computer achieves high accuracy and practicability in signal analysis, processing, and result display. Second, in the aspect of noise signal processing, the characteristics of noise signals are analyzed. It is pointed out that accurately analyzing the characteristics of different noise source signals and adopting appropriate methods for identification and processing are the necessary conditions for effectively controlling and reducing the noise in the process of high-speed cutting. The advantages and applicable fields of artificial intelligence algorithms in processing mixed noise source signals with different frequency characteristics are compared, providing ideas for studying the mechanism of noise generation and the identification of noise sources. Third, in terms of noise control, a detailed overview is provided from the aspects of the treatment of the noise source that contributes the most to the overall noise, the improvement of the tool structure, the optimization of cutting parameters, and the analysis of contact factors between the tool and the workpiece. It provides an effective way for noise control in the process of high-speed cutting. In addition, the application of acoustic signals to condition monitoring is also thoroughly analyzed. The practical application value of condition monitoring based on acoustic signals in high-speed machining is highlighted. Finally, this paper summarizes the positive significance of noise research in high-speed machining and identifies key problems and possible research methods that require further study in the future.

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Section: Noise Signal Acquisition and Numerical Analysis And Noise Co...mentioning

confidence: 99%

Section: Noise Signal Acquisition and Numerical Analysis And Noise Co...mentioning

confidence: 99%

Research Progress of Noise in High-Speed Cutting Machining

Wei

Shang

Peng

et al. 2022

Sensors

View full text Add to dashboard Cite

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“…In the area of environmental ergonomics, the exposure of the employee to the different environmental factors is studied (such as noise [158], vibrations [159], cutting fluids [160] or emissions, toxic mist and air quality [161,162]). The consequences of performing the machining task, on the employee's health, are also evaluated [163,164].…”

Section: Human-machine (H-m) Interactionmentioning

confidence: 99%

A Review of Sustainable Machining Engineering: Optimization Process Through Triple Bottom Line

Álvarez

Bárcena

González

2016

Journal of Manufacturing Science and Engineering

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The studies about sustainable manufacturing engineering (SME) contain an increasing body of knowledge, motivated by the rising interest in the processes lifecycle sustainability. Its continuous improvement and optimization (including sustainability criteria) has become an emerging necessity. For this reason, new clean technologies and proposals of work methods are required; they have to integrate the ecological and social dimensions at an operational level in the manufacturing processes, maintaining the economic and technical feasibility attained up to this moment. However, a unified framework does not exist to orientate the lines of research in optimization when applied to sustainability. In this sense, the article reviews studies from scientific literature about sustainable machining developed in the last 15 years. The review has been carried out from the triple bottom-line (TBL) perspective, defined by the three general sustainability dimensions (economy, ecology, and equity). It contributes to the literature and current machining engineering knowledge, with its involvement in mitigating the metabolic rift. The results from the review have allowed to characterize the investigation effort, with regard to the optimization of the sustainable machining processes; even though numerous studies exist which optimize machining operations (with the aim to find the trade-off between different environmental and equity factors), in general, the technical and economic feasibilities are still the priority. The patterns defined through the analysis of the publications have established the current development trend; furthermore, as a consequence of the review results, we propose an outline of articulated lines of investigation with the aim to mitigate the metabolic rift through triple bottom-line, necessary so that machining engineering assumes the goal of finding the balance to achieve integral sustainability.

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“…For instance, one of the main noise sources is the rotating cutters. The noise level generated by the face milling cutters in operation is usually high, ranging from 85 dB to 105 dB [1]. Even when idling, face milling cutters can produce noise levels up to 95 dB at 13,000 rpm [2].…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis of Aeroacoustic Noise for High-Speed Face Milling Cutters in Three Dimensional Unsteady Flow Fields

Ji¹,

Wang

2012

Journal of Manufacturing Science and Engineering

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Aeroacoustic noise produced by high speed face milling cutters is a serious environmental concern. This paper develops a modeling approach to investigate the aeroacoustic noise generation and propagation by the idling face milling cutters. The approach consists of two parts: (1) an aerodynamic model for evaluating the flow fields based on the Navier-Stokes (N-S) equation and (2) an aeroacoustic model for predicting the acoustic noise by using the Ffowcs Williams and Hawkings (FW-H) equation. Both the steady mode with the multiple reference frames (MRF) model and the unsteady mode with the sliding mesh technique by introducing steady flow variables as its initial flelds are simulated. The cutter gullet regions and the insert rake face regions are found to be tiie primary contributors in noise generation through spectral analysis of noise sources.The acoustic noise in face milling is signiflcantly affected by tiie cutter diameter and the number of cutter teeth. The noise directivity is found in vertical plane, and the irregular tooth spacing can spread the maximum sound power at the rotating frequency to higher frequencies. In addition, experiments are conducted to measure the acoustic noise from two high speed milling cutters. It is found that the experimental results are generally in good agreement with the simulations.

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Modeling and Prediction of Cutting Noise in the Face-Milling Process

Cited by 11 publications

References 2 publications

Research Progress of Noise in High-Speed Cutting Machining

Research Progress of Noise in High-Speed Cutting Machining

A Review of Sustainable Machining Engineering: Optimization Process Through Triple Bottom Line

Numerical Analysis of Aeroacoustic Noise for High-Speed Face Milling Cutters in Three Dimensional Unsteady Flow Fields

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