Near net-shape five-axis face milling of marine propellers

Park, Jung-Whan; Lee, Jung-Geun; Jun, Cha-Soo

doi:10.1007/s12541-009-0065-5

Cited by 11 publications

(4 citation statements)

References 20 publications

(16 reference statements)

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“…However, in recent years, high-speed machining (HSM) has shown the ability to manufacture features in a single pass, an example of which has been subsequently presented in this work as a case study. Moreover, metal cutting operations are also being optimized for hewing to product shapes and hence remove the least amount of stock for achieving requisite tolerances [ 38 ], all akin to production of NNSs. Also, recently, metal cutting has been unusually used as a single-pass severe plastic deformation (SPD) process for producing novel ultra-fine-grained (UFG) materials [ 39 ] whose lesser usage, due to their superior mechanical properties, create frugal products.…”

Section: Candidate Processes For Frugal Manufacturingmentioning

confidence: 99%

Frugal manufacturing in smart factories for widespread sustainable development

Rao

2021

R. Soc. open sci.

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Manufacturing is a crucial activity of product development that feeds into and is also influenced by the design process. Any material conservation gained during manufacturing directly affects the green credentials of a product. Manufacturing waste can be contrived to approach zero through a recently developed frugal design approach that quantifies resource conservation at all stages of development of a product engineered for frugality. Accordingly, this effort presents frugal manufacturing (FM), integral to the frugal design approach , for utmost reduction of waste while aiming for good surface integrity, better properties, minimal number of processes and low cost. Other than saving on energy and hence emissions, the new concept of FM also goes beyond current near net shape technologies, which advocate mainly for zero wastage and suitable properties while using a narrow range of manufacturing processes. Case studies involving high-speed machining , superplastic forming and additive manufacturing of aerospace alloys have been presented that bring out the features and benefits of FM. As such the multipronged objectives of FM should be dovetailed with those of smart factories for creating novel technologies that abet widespread sustainable development. Such enhancement of the smart factories concept has been argued to support unusual applications such as the fight against pandemics including the current one involving COVID-19.

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Section: Candidate Processes For Frugal Manufacturingmentioning

confidence: 99%

Frugal manufacturing in smart factories for widespread sustainable development

Rao

2021

R. Soc. open sci.

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“…Bewlay et al 64 develop roll forming for engine disk, comparing its microstructure, mechanical properties and material wastage with conventional hot forging process (Figure 11). Park et al 65 investigate the machining of turbine blades and report the experimental optimization for tool positioning in the context of NNS production.…”

Section: Empirical-experimentalmentioning

confidence: 99%

Near net shape manufacturing of metal: A review of approaches and their evolutions

Marini

Cunningham

Corney

2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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In the last thirty years the concept of manufacturability has been applied to many different processes in numerous industries. This has resulted in the emergence of several different "Design for Manufacturing" methodologies which have in common the aim of reducing productions costs through the application of general manufacturing rules. Near net shape technologies have expanded these concepts, targeting mainly primary shaping process, such as casting or forging. The desired outcomes of manufacturability analysis for near-net-shape (NNS) processes are cost and lead/time reduction through minimization of process steps (in particular cutting and finishing operations) and raw material saving. Product quality improvement, variability reduction and component design functionality enhancement are also achievable through NNS optimization. Process parameters, product design and material selection are the changing variables in a manufacturing chain that interact in complex, non-linear ways. Consequently modeling and simulation play important roles in the investigation of alternative approaches. However defining the manufacturing capability of different processes is also a "moving target" because the various NNS technologies are constantly improving and evolving so there is challenge in accurately reflecting their requirements and capabilities. In the last decade, for example, CAD, CNC technologies and innovation in materials have impacted enormously on the development of NNS technologies. This paper reviews the different methods reported for NNS manufacturability assessment and examines how they can make an impact on cost, quality and process variability in the context of a specific production volume. The discussion identifies a lack of structured approaches, poor connection with process optimization methodologies and a lack of empirical models as gaps in the reported approaches.

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“…Tool path planning is a challenging task in most 5-axis machining operations, with tool collision and machining error control as two major concerns. 1 It is highly difficult, if not impossible, to completely avoid tool overcut and undercut when a cylindrical cutter is used to create complex shapes. The machined surface is considered acceptable in practice as long as the amount of machining error is limited within a given tolerance.…”

Section: Introductionmentioning

confidence: 99%

Optimization of tool path planning in 5-axis flank milling of ruled surfaces with improved PSO

Hsieh

Chu

2012

Int. J. Precis. Eng. Manuf.

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Previous studies have shown that machining error in 5-axis flank milling can be systematically reduced by optimization of tool path planning. However, the solution quality of the optimization methods adopted by those studies was not satisfactory, due to the constraint that the cutter must contact the boundary curves of the ruled surface to be machined. This work proposes an improved tool path planning method based on Particle Swarm Optimization (PSO) algorithms without this constraint. The method enlarges the feasible region in the optimization by allowing cutter location to deviate the boundary curves along the normal, tangent, and bi-normal directions. Design of experiment techniques are applied to determine better parameter setting in the PSO. A new objective function is formulated as the weighted sum of the errors induced by overcut and undercut. We can choose to minimize the total machining error, the overcut, or the undercut by properly adjusting the weight value. Compared to previous methods, the improved path planning method produces smaller machining error and offers better planning flexibility.

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Near net-shape five-axis face milling of marine propellers

Cited by 11 publications

References 20 publications

Frugal manufacturing in smart factories for widespread sustainable development

Frugal manufacturing in smart factories for widespread sustainable development

Near net shape manufacturing of metal: A review of approaches and their evolutions

Optimization of tool path planning in 5-axis flank milling of ruled surfaces with improved PSO

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