The influence of end mill helix angle on high performance milling process

Płodzień, Marcin; Burek, Jan; Żyłka, Łukasz; Sułkowicz, Paweł

doi:10.1007/s12206-020-0131-6

Cited by 12 publications

(4 citation statements)

References 29 publications

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“…It has been experimentally found that feedrate has the highest effect collectively on energy consumption, surface roughness, and vibration [229]. Cutting tool selection is also an essential factor in process optimization, since it determines the range of cutting parameters [144,230]. The optimization of cutting parameters, incorporation of eco-friendly lubricants, and exploration of energy-efficient machining technologies are building blocks of the I5.0 paradigm shift.…”

Section: Process Sustainabilitymentioning

confidence: 99%

Cyber–Physical Systems for High-Performance Machining of Difficult to Cut Materials in I5.0 Era—A Review

Gohari,

Hassan,

Shi

et al. 2024

Sensors

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The fifth Industrial revolution (I5.0) prioritizes resilience and sustainability, integrating cognitive cyber-physical systems and advanced technologies to enhance machining processes. Numerous research studies have been conducted to optimize machining operations by identifying and reducing sources of uncertainty and estimating the optimal cutting parameters. Virtual modeling and Tool Condition Monitoring (TCM) methodologies have been developed to assess the cutting states during machining processes. With a precise estimation of cutting states, the safety margin necessary to deal with uncertainties can be reduced, resulting in improved process productivity. This paper reviews the recent advances in high-performance machining systems, with a focus on cyber-physical models developed for the cutting operation of difficult-to-cut materials using cemented carbide tools. An overview of the literature and background on the advances in offline and online process optimization approaches are presented. Process optimization objectives such as tool life utilization, dynamic stability, enhanced productivity, improved machined part quality, reduced energy consumption, and carbon emissions are independently investigated for these offline and online optimization methods. Addressing the critical objectives and constraints prevalent in industrial applications, this paper explores the challenges and opportunities inherent to developing a robust cyber–physical optimization system.

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Section: Process Sustainabilitymentioning

confidence: 99%

Cyber–Physical Systems for High-Performance Machining of Difficult to Cut Materials in I5.0 Era—A Review

Gohari,

Hassan,

Shi

et al. 2024

Sensors

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“…The advantage of this method is the possibility of mac arc fir tree slots [58][59][60][61][62]. Jianhua et al noticed that milling in a single machining pass may lead to sub the cutter to very high thermal loads and, as a result, accelerated tool wear (Figu Therefore, dividing the profile of the slot into a few parts and machining the subse sides and bottom of the slot was proposed [63][64][65][66]. Surface roughness after milli pending on the machining strategy is usually in the range of approximately Rz 2.1 5.9 μm [67][68][69].…”

Section: Millingmentioning

confidence: 99%

“…the cutter to very high thermal loads and, as a result, accelerated tool we Therefore, dividing the profile of the slot into a few parts and machining t sides and bottom of the slot was proposed [63][64][65][66]. Surface roughness af pending on the machining strategy is usually in the range of approximate 5.9 μm [67][68][69].…”

Section: Millingmentioning

confidence: 99%

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

2023

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This review article presents a summary of currently used and proposed methods of manufacturing fir tree slots of discs in turbine engines. The production of aircraft, including aircraft engines during times of overlapping global economic crises related to the COVID-19 pandemic or the war in Eastern Europe requires a quick response to the changing numbers of passengers and cargo. Similarly, the aviation industry must adapt to these conditions, and thus utilize flexible production methods allowing for a quick change in the design or type of a given part. Due to the constant adoption of new materials for the most critical aero engine parts and the necessity of complying with environmental regulations, it is necessary to search for new methods of manufacturing these parts, including fir tree slots. As an alternative to currently used expensive and energy-intensive broaching, many manufacturers try to implement creep feed grinding CFG or contour milling. However, other manufacturing methods, thus far rarely used for crucial machine parts such as WEDM, ECDM or AWJ, are gaining more and more popularity in the aviation industry. This article presents the advantages and shortcomings of these methods in the context of manufacturing fir tree slots.

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“…and b is the constant helical angle between the tangent vector of the cutting edge at that point and the tool axis. 25 To describe the characteristics of wheel accurately, define the grinding wheel coordinate system as GCS to describe profile shape of wheel, origin O g as the center of the front face of wheel, axis X g as the vector from point P to origin O g , axis Z g as the axis of wheel, F g as the axis vector of wheel, and F b as the vector from point P to origin O g . So, the wheel position can be expressed by vector F g and coordinates of origin O g .…”

Section: The Theoretical Tool Path Of Ideal Grinding Wheelmentioning

confidence: 99%

A compensation algorithm of tool path for grinding wheel wear in solid cutting tool flank grinding

Jiang

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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In finishing machining, the quality of workpiece is significantly influenced by the performance of solid cutting tool. Solid cutting tool flank is ground by CNC tool grinder in accordance with the tool path of grinding wheel. In actual grinding process, the grinding area of wheel will be gradually worn down, resulting in the decrease of geometric accuracy of flank and even wrong profile. In order to compensate the error, a compensation algorithm of tool path for solid cutting tool flank based on grinding wheel wear is proposed. Firstly, the coordinate systems are defined for the grinding process of flank, and the orientation and location calculation model of ideal wheel with the grinding process parameters is derived. Secondly, based on the profile description of wheel wear, flank errors are analyzed. Then, the compensation algorithm for anastomosis of cutting edge and relief angle is proposed. Finally, series of experiments of simulation and actual grinding are carried out. The comparison of the results shows that the algorithm can reduce the influence of wheel wear effectively, which can also improve the grinding quality stability and prolong the service life of grinding wheel.

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The influence of end mill helix angle on high performance milling process

Cited by 12 publications

References 29 publications

Cyber–Physical Systems for High-Performance Machining of Difficult to Cut Materials in I5.0 Era—A Review

Cyber–Physical Systems for High-Performance Machining of Difficult to Cut Materials in I5.0 Era—A Review

The Review of Current and Proposed Methods of Manufacturing Fir Tree Slots of Turbine Aero Engine Discs

A compensation algorithm of tool path for grinding wheel wear in solid cutting tool flank grinding

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