Development of a machining simulator considering machine behaviour

2003 ◽  
Vol 217 (9) ◽  
pp. 1333-1339 ◽  
Author(s):  
A Dugas ◽  
J J Lee ◽  
M Terrier ◽  
J Y Hascoët
Keyword(s):  
High Speed ◽  
Dynamic Behaviour ◽  
Three Dimensional ◽  
Milling Process ◽  
High Speed Machining ◽  
Tracking Errors ◽  
Tool Paths ◽  
Milling Operation ◽  
Dynamic Errors ◽  
Tool Deflections

High-speed machining gives much potential for increasing the efficiency of the milling operation, but it requires very careful preparation for the milling process to use this potential. A machining simulator has been developed that can analyse dynamic errors due to tool deflections and machine dynamic behaviour using a three-dimensional solid simulation model. This kind of simulator would be a useful tool to apply in high-speed machining where it is necessary to obtain very well prepared part programs considering dynamic errors as well as geometrical errors. In this short communication, an algorithm will be introduced to estimate the dynamic errors caused by machine dynamic behaviour. Specifically, this algorithm predicts real feed rates and tracking errors considering the limits of numerical controllers and machine tools. The efficiency of the algorithm has been verified through several experiments with various tool paths. In addition, the algorithm has been integrated into the machining simulator. Some results obtained from the machining simulator concerning the estimation of tracking errors will be reported.

Analysis and Research of High Speed Milling of Thin-Walled Bracket Part Based on UG NX

2010 ◽  
Vol 129-131 ◽  
pp. 256-260
Author(s):  
Yi Shu Hao ◽  
Chuang Hai ◽  
Xin Xing Zhu
Keyword(s):  
High Speed ◽  
Three Dimensional ◽  
Structural Features ◽  
Milling Process ◽  
Analysis Method ◽  
Three Dimensional Model ◽  
Machining Processes ◽  
Element Analysis ◽  
High Speed Milling ◽  
Tool Paths

Treating high speed milling theory as the guidance, this paper researched high speed milling process of bracket part based on UG NX. Combined with the structural features of bracket part, three dimensional model is built by UG NX CAD and machining processes are worked out after analysis. UG CAM module was applied to fabricate tool paths. At last, finite element analysis method is introduced to study the processing deformation by UG NX NASTRAN module, based on which measures to restrain processing deformations is advanced and processing sequences are optimized.

Based on Pro/E High Speed Milling of Thin-Walled Stents of Research

2011 ◽  
Vol 295-297 ◽  
pp. 2487-2491
Author(s):  
Jian Qiang Wang
Keyword(s):  
High Speed ◽  
Three Dimensional ◽  
Structural Features ◽  
Milling Process ◽  
Analysis Method ◽  
Three Dimensional Model ◽  
Machining Processes ◽  
Element Analysis ◽  
High Speed Milling ◽  
Tool Paths

Treating high speed milling theory as the guidance, this paper researched high speed milling process of bracket part based on Pro/E. Combined with the structural features of bracket part, three dimensional model is built by Pro/E and machining processes are worked out after analysis. Pro/E module was applied to fabricate tool paths. At last, finite element analysis method is introduced to study the processing deformation by Pro/E module, based on which measures to restrain processing deformations is advanced and processing sequences are optimized.

Tool Overhang Effect on Cutting Force in High Speed Milling

2010 ◽  
Vol 34-35 ◽  
pp. 616-620 ◽  
Author(s):  
Zhen Yu Zhao ◽  
Ying Bin Du ◽  
Lei Ming Zhang ◽  
Bai Liu
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Milling Process ◽  
Processing Capacity ◽  
High Speed Machining ◽  
High Speed Milling ◽  
Rational Use ◽  
High Speed Impact ◽  
Overhang Length

Based on the amount of tool overhang under different high speed machining experiment, the overhang length on the high speed impact of cutting force in milling process is studies. On the basis, the proposed tool overhang and optimum program are proposed in high speed milling, through the rational use of tools to improve processing capacity of the tool.

Study on High Speed Machining Strategies for Mold

2012 ◽  
Vol 591-593 ◽  
pp. 468-471
Author(s):  
Yong Xia Liu ◽  
Ru Shu Peng ◽  
Qiang Cheng
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
High Speed ◽  
Intake Manifold ◽  
High Speed Machining ◽  
Machining Time ◽  
High Speed Milling ◽  
Tool Paths ◽  
Nc Program ◽  
Machining Strategies

The advantages and current problems for the application of high-speed machining technology in mold manufacturing are discussed. The requirements of mold high-speed machining for tool paths are summarized. Using the software of Cimatron E7.0，the NC program of the outer mold for a car engine’s V8 intake manifold is analyzed and optimized designed. Programming technology and optional of cutters have been introduced in detail. In the high speed milling stages, using the new cutters, the hardened mold can be machined to reach the required size, shape and surface roughness, and the machining time is reduced greatly. The method of making high speed NC template based on the software Cimatron E7.0. is introduced. Using this method, the maching efficiency is improved greatly, and the mold’ s surface quality better.

Simulation of Three-Dimensional Dynamic Cutting Forces and Chatter Stability in Ball-End Milling

2010 ◽  
Vol 443 ◽  
pp. 302-307
Author(s):  
Jun Zhao ◽  
Xiao Feng Zhang ◽  
Han Bing Luo
Keyword(s):  
High Speed ◽  
End Milling ◽  
Three Dimensional ◽  
Milling Process ◽  
Ball End Milling ◽  
Parameters Selection ◽  
Nonlinear Dynamics Model ◽  
Dynamic Components ◽  
The Stability ◽  
Milling Forces

By taking into account the regenerative chatter vibration, a nonlinear dynamics model for high speed ball-end milling is proposed. The effect of dynamic components of milling forces on chatter is analyzed. A method to predict the stability limits of high speed ball-end milling process is proposed and the stability lobes diagram is simulated. The comparison of experimental milling forces with the simulation results indicates the high accuracy of the model and the effectiveness of the simulation algorithms. The proposed method provides a theoretical instruction for parameters selection and optimization in milling processing.

3D Finite Element Modeling of High Speed Machining

2012 ◽  
pp. 178-196
Author(s):  
A.P. Markopoulos ◽  
K. Kantzavelos ◽  
N.I. Galanis ◽  
D.E. Manolakos
Keyword(s):  
Finite Element ◽  
Experimental Work ◽  
High Speed ◽  
Three Dimensional ◽  
Chip Morphology ◽  
Third Wave ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Morphology Model ◽  
Coated Carbide

This paper presents simulation of High Speed Machining of steel with coated carbide tools. More specifically, Third Wave Systems AdvantEdge commercial Finite Element Method code is employed in order to present turning models, under various machining conditions. As a novelty, the proposed models for High Speed Machining of steel are three-dimensional and are able to provide predictions on cutting forces, tool and workpiece temperatures, chip formation, and chip morphology. Model validation is achieved through experimental work carried out under the same conditions as the ones used in modeling. For the experimental work, the principles for design of experiment were used in order to minimize the required amount of experiments and obtain useful results at the same time. Furthermore, a Taguchi analysis is carried out based on the results. The analysis indicates that there is a good agreement between experiment and modeling, and the proposed models can be further employed for the prediction of a range of machining parameters, under similar conditions.

Automatic In-Process Chatter Avoidance in the High-Speed Milling Process

2010 ◽  
Vol 132 (3) ◽  
Author(s):  
N. J. M. van Dijk ◽  
E. J. J. Doppenberg ◽  
R. P. H. Faassen ◽  
N. van de Wouw ◽  
J. A. J. Oosterling ◽  
...  
Keyword(s):  
High Speed ◽  
Control Strategies ◽  
Detection Algorithm ◽  
Milling Process ◽  
Process Conditions ◽  
High Speed Milling ◽  
Milling Operations ◽  
Milling Operation ◽  
Automatic Adaptation ◽  
And Control

High-speed milling is often used in industry to maximize productivity of the manufacturing of high-technology components, such as aeronautical components, mold, and dies. The occurrence of chatter highly limits the efficiency and accuracy of high-speed milling operations. In this paper, two control strategies are presented that guarantee a chatter-free high-speed milling operation by automatic adaptation of spindle speed and feed. Moreover, the proposed strategies are robust for changing process conditions (e.g., due to heating of the spindle or tool wear). An important part of the control strategy is the detection of chatter. A novel chatter detection algorithm is presented that automatically detects chatter in an online fashion and in a premature phase such that no visible marks on the workpiece are present. Experiments on a state-of-the-art high-speed milling machine underline the effectiveness of the proposed detection and control strategies.

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