Analytical derivation of thread profile in internal thread milling process

2021 ◽  
pp. 095440892110560
Author(s):  
Ahmet Dogrusadik
Keyword(s):  
Vertical Axis ◽  
Milling Process ◽  
Cutting Edge ◽  
Numerical Control ◽  
Machining Process ◽  
Internal Thread ◽  
Machining Processes ◽  
Thread Profile ◽  
Long Time ◽  
Thread Milling

Thread milling is a new machining process as compared to thread tapping. As a thread making process in use for a long time, thread tapping did not have any alternative processes except the thread turning for limited cases until computer numerical control (CNC) technology had enabled the three axes synchronized motion. Therefore, investigations about the thread milling process are less as compared to other machining processes. In this work, the thread profile in the internal thread milling process was derived analytically. Experimental work was also performed to verify the performance of the analytical model. It was revealed that the thread profile produced by the cutting edge of the tool is not a straight line but a curve, and the average slope through the thread profile is less than the slope of the cutting edge of the tool. Besides, the effective thread profile enlarges along the vertical axis and constricts laterally as the ratio of thread mill diameter to thread diameter increases.

Schneidkantenpräparation von VHM-Mikrofräsern*/Cutting edge preparation of cemented carbide micro milling tools – A comparison of different fine machining processes

2015 ◽  
Vol 105 (11-12) ◽  
pp. 805-811
Author(s):  
E. Uhlmann ◽  
D. Oberschmidt ◽  
A. Löwenstein ◽  
M. Polte ◽  
I. Winker
Keyword(s):  
Tool Wear ◽  
Milling Process ◽  
Cutting Edge ◽  
Micro Milling ◽  
Machining Processes ◽  
Process Reliability ◽  
Cutting Edge Preparation ◽  
Milling Tools ◽  
Edge Preparation

Die Prozesssicherheit beim Mikrofräsen lässt sich mit einer gezielten Schneidkantenverrundung erheblich steigern. Dabei werden durch verschiedene Präparationstechnologien unterschiedliche Geometrien und Einflüsse auf den Fräsprozess erzeugt. Der Fachbeitrag behandelt den Einsatz präparierter Mikrowerkzeuge in Zerspanversuchen, in denen auf die Zerspankräfte, den Verschleiß sowie die Oberflächengüten eingegangen wird.   Process reliability in micro milling can be increased by a defined cutting edge preparation. Different cutting edge preparations cause different effects on tool behavior in the downstream micro milling process. In this paper, the process forces, the tool wear and the surface quality of prepared micro milling tools are characterized in cutting tests.

scholarly journals Automatic Temperature Measurement and Monitoring System for Milling Process of AA6041 Aluminum Aloy using MLX90614 Infrared Thermometer Sensor with Arduino

2021 ◽  
Vol 82 (2) ◽  
pp. 1-14
Author(s):  
Agus Sudianto ◽  
Zamberi Jamaludin ◽  
Azrul Azwan Abdul Rahman ◽  
Sentot Novianto ◽  
Fajar Muharrom
Keyword(s):  
Aluminum Alloy ◽  
Temperature Measurement ◽  
Monitoring System ◽  
Measurement System ◽  
Manufacturing Process ◽  
Milling Process ◽  
Numerical Control ◽  
Machining Process ◽  
Infrared Thermometer ◽  
Temperature Measurement System

Manufacturing process of metal part requires real-time temperature monitoring capability to ensure high surface integrity is upheld throughout the machining process. A smart temperature measurement and monitoring system for manufacturing process of metal parts is necessary to meet quality and productivity requirements. A smart temperature measurement can be applied in machining processes of conventional, non-conventional and computer numerical control (CNC) machines. Currently, an infrared fusion based thermometer Fluke Ti400 was employed for temperature measurement in a machining process. However, measured temperature in the form of data list with adjustable time range setting is not automatically linked to the computer for continuous monitoring and data analysis purposes. For this reason, a smart temperature measurement system was developed for a CNC milling operation on aluminum alloy (AA6041) using a MLX90614 infrared thermometer sensor operated by Arduino. The system enables data linkages with the computer because MLX90614 is compatible and linked to Microsoft Exel via the Arduino. This paper presents a work-study on the performance of this Arduino based temperature measurement system for dry milling process application. Here, the Arduino based temperature measurement system captured the workpiece temperature during machining of Aluminum Alloy (AA6041) and data were compared with the Fluke Ti400 infrared thermometer. Measurement results from both devices showed similar accuracy level with a deviation of ± 2 oC. Hence, a smart temperature measurement system was succeesfully developed expanding the scopes of current system setup.

scholarly journals Machining Process for a Thin-Walled Workpiece Using On-Machine Measurement of the Workpiece Compliance

2019 ◽  
Vol 13 (5) ◽  
pp. 631-638 ◽  
Author(s):  
Takuma Umezu ◽  
◽  
Daisuke Kono
Keyword(s):  
Measurement System ◽  
End Milling ◽  
Numerical Control ◽  
Cutting Conditions ◽  
Machining Process ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Workpiece Vibration ◽  
Thin Walled

Demand for highly productive machining of thin-walled workpieces has been growing in the aerospace industry. Workpiece vibration is a critical issue that could limit the productivity of such machining processes. This study proposes a machining process for thin-walled workpieces that aims to reduce the workpiece vibration during the machining process. The workpiece compliance is measured using an on-machine measurement system to obtain the cutting conditions and utilize the same for suppressing the vibration. The on-machine measurement system consists of a shaker with a force sensor attached on the machine tool spindle, and an excitation control system which is incorporated within the machine tool’s numerical control (NC). A separate sensor to obtain the workpiece displacement is not required for the estimation of the displacement. The system is also capable of automatic measurement at various measurement points because the NC controls the positioning and the preloading of the shaker. The amplitude of the workpiece vibration is simulated using the measured compliance to obtain the cutting conditions for suppressing the vibration. An end milling experiment was conducted to verify the validity of the proposed process. The simulations with the compliance measurement using the developed system were compared to the results of a conventional impact test. The comparison showed that the spindle rotation speed for suppressing the vibration could be successfully determined; but, the axial depth of cut was difficult to be determined because the simulated vibration amplitude was larger than that found in the experimental result. However, this can be achieved if the amplitude is calibrated by one machining trial.

Monitoring and Control of Thermal Expansion Effect on Machining Process of Aluminum Alloy Parts

2015 ◽  
Vol 809-810 ◽  
pp. 33-38 ◽  
Author(s):  
Ştefan Adrian Moldovan ◽  
Vasile Năsui
Keyword(s):  
Thermal Expansion ◽  
Aluminum Alloy ◽  
Milling Process ◽  
Machining Process ◽  
Machining Accuracy ◽  
Technological Problem ◽  
Monitoring And Control ◽  
Machining Processes ◽  
Thermal Expansion Effect ◽  
Expansion Effect

In this paper we present a technological problem encountered in the machining accuracy of the parts for aerospace made of aluminum alloy extruded profile with length up to 10 meters. Those parts have very tight tolerances and on milling process appear several factors that influence the repeatability of machining processes, the main one being the thermal expansion effect.

scholarly journals Non-Invasive Estimation of Machining Parameters during End-Milling Operations Based on Acoustic Emission

Sensors ◽  
2020 ◽  
Vol 20 (18) ◽  
pp. 5326
Author(s):  
Andrés Sio-Sever ◽  
Erardo Leal-Muñoz ◽  
Juan Manuel Lopez-Navarro ◽  
Ricardo Alzugaray-Franz ◽  
Antonio Vizan-Idoipe ◽  
...  
Keyword(s):  
Acoustic Emission ◽  
End Milling ◽  
Low Cost ◽  
Milling Process ◽  
Machining Process ◽  
Measuring System ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machining Processes ◽  
Non Invasive

This work presents a non-invasive and low-cost alternative to traditional methods for measuring the performance of machining processes directly on existing machine tools. A prototype measuring system has been developed based on non-contact microphones, a custom designed signal conditioning board and signal processing techniques that take advantage of the underlying physics of the machining process. Experiments have been conducted to estimate the depth of cut during end-milling process by means of the measurement of the acoustic emission energy generated during operation. Moreover, the predicted values have been compared with well established methods based on cutting forces measured by dynamometers.

Analysis on the NC Milling Machining Precision and the Error

2014 ◽  
Vol 926-930 ◽  
pp. 1214-1217
Author(s):  
Bo Tang
Keyword(s):  
Process Design ◽  
Process Analysis ◽  
Milling Process ◽  
Numerical Control ◽  
Machining Process ◽  
Cnc Milling ◽  
Machining Precision ◽  
Cnc Milling Machine ◽  
Process Route ◽  
Nc Milling

the numerical control milling process design is on the basis of ordinary milling process design, combining with the characteristics of CNC milling machine, give full play to its advantages. CNC milling process design is the key to reasonable arrangement of process route, to coordinate the relationship between the CNC milling process and other process, determine the content and steps of NC milling process make the necessary preparations for programming. NC milling machining process analysis is related to the effectiveness and success or failure, is one of the important preparations before programming. This article will mainly for NC milling machining precision and machining error analysis and research.

Empirical study on ultrasonic assisted turn-milling

2021 ◽  
pp. 095440892110087
Author(s):  
Saeid Amini ◽  
Mohammad Baraheni ◽  
Mohammad Khaki
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Feed Rate ◽  
Rotational Speed ◽  
Milling Process ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Turn Milling

Turn-milling process has been paid attention in order to be used in multi-task machining processes. Moreover, looking for new machining techniques aimed at reducing cutting force is of important. Reducing cutting force in machining processes has the benefits of extending tool life and improving surface quality. One of the new concepts for reducing the cutting force is applying ultrasonic vibration. In this paper, effects of ultrasonic vibration under different machining parameters in turn-milling process of Al-7075 alloy will be investigated. In this order, a special mechanism was designed to apply ultrasonic vibration during machining process. Ultrasonic vibration exertion on the tool reduced cutting force and surface roughness up to 75% and 35%, respectively. Also tool rotational speed increment induced cutting force and surface roughness increment. In addition, tool feed rate and workpiece rotational speed increment caused cutting force and surface roughness increment. Although, feed rate was more influential.

Comparison of minimum quantity lubrication and wet milling based on energy consumption modeling

2021 ◽  
pp. 095440892110144
Author(s):  
Masuod Bayat ◽  
Mohammad Mahdi Abootorabi
Keyword(s):  
Energy Consumption ◽  
Manufacturing Industry ◽  
Minimum Quantity Lubrication ◽  
Milling Process ◽  
Numerical Control ◽  
Machining Process ◽  
Wet Milling ◽  
Total Energy Consumption ◽  
Minimum Quantity ◽  
Energy Consumption Modeling

Estimating the energy consumed by machining process is substantial because it has a large share of environmental effects in the manufacturing industry. In this paper, a generic energy consumption model was developed for milling processes that is able to be applied in all milling machine tools. Energy consumption of each segment was estimated according to power characteristics and parameters extracted from numerical control (NC) codes, then the total energy consumption was estimated by adding energy consumption of the machine components. Energy consumption of milling process was measured and compared in conventional (wet) and minimum quantity lubrication (MQL) conditions. The developed method was verified by comparing the estimated values of energy consumption with experimental results. Various studies have suggested different types of energy consumption modeling with machining, however; only a few studies have focused on the use of these modeling techniques. Thus, the MQL method has been rarely compared with the wet milling in terms of energy consumption. In the proposed model, energy consumption for workpiece adjustment, accounting for a major part of the costs in machining economics was considered for the first time. The results showed that the proposed method is efficient and practical for predicting energy consumption, with the possibility of occurring 5% error. Analysis of the results revealed that using the MQL method in milling process leads to 33% lower power consumption than wet milling and therefore, the MQL method can reduce the cost of production.

Fuzzy Modeling on the Basis of FCM Technique: A Case Study Aiming at Process Supervision

2001 ◽  
Author(s):  
Rodolfo E. Haber Guerra ◽  
Rodolfo Haber Haber ◽  
Angel Alique ◽  
Clodeinir R. Peres ◽  
Salvador Ros
Keyword(s):  
Fuzzy Model ◽  
Main Idea ◽  
Nonlinear Behavior ◽  
Milling Process ◽  
Machining Process ◽  
Machining Processes ◽  
Complex Processes ◽  
Tool Performance ◽  
Process Supervision

Abstract The nonlinear behavior and complexity of machining processes have motivated researchers to use fuzzy model to effect process supervision. The main idea of this paper concerns the application of fuzzy logic and clustering techniques to develop a fuzzy model of the milling process aiming at the optimization of machine-tool performance and the overall machining process. A brief description of the algorithm employed is given, focused on the fuzzy c-mean technique (FCM). The results indicate that the FCM criterion is suitable for modeling complex processes such as the milling process. The fuzzy model obtained serves as foundation to develop complex supervisory systems.

scholarly journals Pembuatan Cetakan Pasir Dan Proses Pemesinan Untuk Komponen Blok Pompa Pada Mesin Pompa Air Merk Matrix Model Mtx-22c

2019 ◽  
Vol 11 (2) ◽  
pp. 47-50
Author(s):  
Firdaus Firdaus ◽  
Rakiman Rakiman ◽  
Nota Effiandi ◽  
Yuli Yetri
Keyword(s):  
Reverse Engineering ◽  
Matrix Model ◽  
Milling Process ◽  
Sand Casting ◽  
Machining Process ◽  
Mold Design ◽  
Drilling Process ◽  
Turning Process ◽  
Machining Processes ◽  
Design Documents

Reverse Engineering (RE) is a process in manufacturing that aims to reproduce or recreate existing models, either components, sub-components, or products without using existing design documents or working drawings. Through this reverse engineering idea, the process of making the Pump Block component is started with making part and mold design, making sand casting, then finished with machining processes. The machining process that is carried out is the turning process, the milling process, and the drilling process which is assisted by using jigs and fixture to make it easier on finishing the Pump Block parts in the machining process. By using the processes, so it is produced the similar pump block that is resemble with desired original object.

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