Precision Manufacturing

Dornfeld, David; Lee, Dae-Eun

doi:10.1007/978-0-387-68208-2

Cited by 117 publications

(71 citation statements)

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“…Existing research in this area can be categorized into three classifications, i.e., Sensitivity Analysis [1,2], End Effector Accuracy Prediction [1,3] and Error Budget [1] of machine tools.…”

Section: Review Of Related Workmentioning

confidence: 99%

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Sculptured surface-oriented machining error synthesis modeling for five-axis machine tool accuracy design optimization

Mou

et al. 2016

Int J Adv Manuf Technol

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Abstract:Customer-oriented design is very important for machine tool manufacturers to win competition in the market. Mechanical parts with complicated sculptured surface are widely utilized in mechanical systems such as automobiles, aircrafts and wind turbines, and they are often machined by five-axis machine tools with high precision requirements. However traditional machine tool design has not accounted for the varied machining errors in producing complex sculptured surface, which leads to inferior performance. To address this challenge, a novel machining error synthesis model is proposed in this paper for accuracy optimization in designing general five-axis machine tools used for making various sculptured surfaces. The new synthesis model bridges between surface machining profile error and the machine tool accuracy, and it is constructed by integrating a generic machine tool volumetric error model and two new surface machining error production models. The synthesis model is then applied as a constraint in machine tool accuracy design optimization. Also a tolerance-cost function is formulated to construct the objective function, and a meta-heuristic algorithm is developed to implement the optimization. All these modeling and optimization methods are validated by one case study.

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Section: Review Of Related Workmentioning

confidence: 99%

“…Error Budget can be defined simply as allocating allowable errors to meet a target machining accuracy [1]. Compared to the two methodologies above, the inner mechanism between the machine tool error input and machining accuracy output are more focused to improve machine tool accuracy level in the Error Budget area.…”

Section: Review Of Related Workmentioning

confidence: 99%

Sculptured surface-oriented machining error synthesis modeling for five-axis machine tool accuracy design optimization

Mou

et al. 2016

Int J Adv Manuf Technol

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“…However, forced vibrations can have significant effects on the quality of metal cutting operations and if they are in lateral directions, they may cause significant surface marks on the wall of the hole. Interested readers may refer to [6][7][8][9][10] for more details on forced vibrations in metal cutting.…”

Section: Introductionmentioning

confidence: 99%

Time domain simulation of chatter vibrations in indexable drills

Parsian

Magnevall

Eynian

et al. 2016

Int J Adv Manuf Technol

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Regenerative chatter vibrations are common in drilling processes. These unwanted vibrations lead to considerable noise levels, damage the quality of the workpiece, and reduce tool life. The aim of this study is to simulate torsional and axial chatter vibrations as they play important roles in dynamic behavior of indexable insert drills with helical chip flutes. While asymmetric indexable drills are not the focal points in most of previous researches, this paper proposes a simulation routine which is adapted for indexable drills. Based on the theory of regenerative chatter vibration, a model is developed to include the asymmetric geometries and loadings that are inherent in the design of many indexable insert drills. Most indexable insert drills have two inserts located at different radial distances, namely central and peripheral inserts. Since the positions of the central and peripheral inserts are different, the displacement and thereby the change in chip thickness differs between the inserts. Additionally, the inserts have different geometries and cutting conditions, e.g., rake angle, coating, and cutting speed, which result in different cutting forces. This paper presents a time-domain simulation of torsional and axial vibrations by considering the differences in dynamics, cutting conditions, and cutting resistance for the central and peripheral inserts on the drill. The time-domain approach is chosen to be able to include nonlinearities in the model arising from the inserts jumping out of cut, multiple delays, backward motions of edges, and variable time delays in the system. The model is used to simulate cutting forces produced by each insert and responses of the system, in the form of displacements, to these forces. It is shown that displacements induced by dynamic torques are larger than those induced by dynamic axial forces. Finally, the vibration of a measurement point is simulated which is favorably comparable to the measurement results.

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“…Here we see the importance of integrating all the elements affecting burrs, from the part design, including material selection, to the machining process. [2] Burr formation affects workpiece accuracy and quality in several ways; dimensional distortion on part edge, challenges to assembly and handling caused by burrs in sensitive locations on the workpiece and damage done to the work subsurface from the deformation associated with burr formation. A typical burr formed on a metal component due to the exit of a cutting edge can range in shape and size from small and uniform (as in a "knife burr") to rather large, nonuniform in shape and many millimeters in length.…”

Section: Introductionmentioning

confidence: 99%

“…Fig. 3 Three typical burrs in drilling stainless steel, Dornfeld and Lee [2] A better strategy is to attempt to prevent of minimize, or prevent, burrs from occurring in the first place. This has two immediate benefits in that, first, it eliminates the additional cost of deburring the component and the likelihood of damage during the deburring process and, second, in the case burrs cannot be eliminated it improves the effectiveness of any deburring strategy due to reduced and more standard burr size and shape.…”

Section: Introductionmentioning

confidence: 99%

A Review of Burr Formation in Machining

Dornfeld

Min

2009

Burrs - Analysis, Control and Removal

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One of the major concerns in deburring technology is centered on how to predict the size and shape of burrs to insure uniform removal and, if this is possible, how to design the process or product in advance to minimize or control the burr size. This paper reviews some of the research done over the past several years on this important topic. The paper includes a discussion of burrs in conventional machining, process planning for burr minimization as well as micromachining applications.

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Precision Manufacturing

Cited by 117 publications

References 0 publications

Sculptured surface-oriented machining error synthesis modeling for five-axis machine tool accuracy design optimization

Sculptured surface-oriented machining error synthesis modeling for five-axis machine tool accuracy design optimization

Time domain simulation of chatter vibrations in indexable drills

A Review of Burr Formation in Machining

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