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The Czech Technical University in Prague Faculty of Mechanical Engineering

Research Center of Manufacturing Technology

Technische Universität Darmstadt The Institute of Production Management,

Technology and Machine Tools

The Czech Technical University in Prague

Ecole Nationale Supérieure d´Arts et Métiers

Nanjing University of Aeronautics and Astronautics

IK4 TeknikerCzech Machine Tool Society

Sponsored by the International Academy for Production Engineering CIRP

11TH INTERNATIONAL CONFERENCE

ADVANCES IN MANUFACTURING TECHNOLOGY

BOOK OF ABSTRACTS

Book of Abstracts Paper Fulltexts

Acknowledgements | Organizers and Partners

Czech Machine Tool Society | CMTSHorská 3, 128 Prague 2, Czech RepublicPhone | +420 221 990 940, Email | [email protected]

11 – 12/9 2014, Prague, Czech Republic | 1

Welcome to the 11th International Conference on High Speed Machining HSM 2014 in Prague! The HSM conference runs every year in various countries of the world. The conference is organized by a consortium of partners involving PTW Darmstadt (Germany), IK4 Tekniker (Spain), Ensam Paritech (France), RCMT – Research Center of Manufacturing Technology (Czech Republic) and NUAA – Nanjing University of Aeronautics and Astronautics (China). This year, the conference is proudly organized in the Czech Republic by RCMT with the sponsorship of the International Academy for Production Engineering CIRP.

The advantages of high speed machining technology were disco-vered by Prof. Solomon at the beginning of 1930s. Significant advances in cutting tool materials and tool coatings accelerated the great progress in high speed machining technology in 1990s. High speed machinings technology brought a new paradigm both to machining strategies and design of machine tools and their components. Still, there are some challenges in the continuous development of high speed machining technology. The HSM 2014 Conference pays attention to all of them:

Mathematical modelling of machining operations | Mathematical modelling of the cutting process facilitates our understanding of process details in the cutting edge and workpiece contact region.

Cutting tool design | Design of cutting tools is a complex task involving aspects of macrogeometry (cutting tool angle), microgeometry (cutting edge geometry and its preparation) and coatings. Cutting tool design strongly influences cutting force magnitude, tool wear resistance and general application possibilities.

Cutting fluids | This wide and important topic involves a wide spectrum of solutions today. Starting with dry and semidry cutting, continuing with MQL and high-pressure cooling up to cryogenic cooling, there are many useful combinations for each specific machining operation and workpiece material.

Mathematical modelling of machines | The virtual machining concept enables us to do accurate simulations of machine tool properties and resultant workpiece quality at the design stage, without the need for expensive and time demanding experimental testing.

Chatter modelling and suppression | Chatter is a special pheno-menon connecting properties of the machine tool, the workpiece and the cutting technology.

Tool path planning | A well prepared NC code is one of the corner-stones of effective machining. It is a complex task involving geo-metrical information on the workpiece, control system interpolator properties, dynamic limits of the machine tool, its feed drives and collision avoidance issues.

Micromachining | The production of parts with specific micro features is essential for current electronic and optical industry. General ma-chining demands remain, but the required tiny dimensions bring new challenges.

We believe that the presented papers will serve as a valuable source of information and also boost research networking in the future. We would like to thank all the authors for their contributions to the conference programme and proceedings. We would also like to express our gratitude to the members of the international scientific committee for their time, effort and constructive feedback, which have helped a great deal in preparing the HSM 2014 Conference.

Thank you again for your support and I wish you a fruitful and pleasant conference!

Dr. Petr KolářChairman of the 11th Inter national Conference

on High Speed Machining HSM 2014

2 | Book of Abstracts of the 11th International Conference on High Speed Machining

CONTENTSThe full versions of all papers are available on the enclosed CD.

KEYNOTE PAPERS

Trends in machine tool design and use/Prof. Zäh 4

Latest developments on high speed cutting machines: improvements of accuracy, speed and enlargement of areaof application/Dr. Gossel

5

High Performance Machining of Aerospace Parts/Prof. He 6

Improvement of die casting life time by machine hammer peening/Prof. Bleicher 7

Session 1: Machine tool and workpiece modelling/chairman: Prof. Zäh

14061 Stiffness improvements in complex portable machine structures by means of topology optimization 8

14089 The modelling of liquid cooling for the efficient reduction of thermal errors in heavy duty machine tools 9

14092 Simulation model for quick predictions of workpiece dynamic response in machining 10

14052 Prediction of the spindle and tool receptance: Industrial application in reaming process 11

Session 2: Machining modelling/Prof. Özel

14019 Coupled eulerian-lagrangian modelling of high speed metal cutting processes 12

14020 Finite element modeling of the orthogonal machining of particle reinforced aluminum based metal matrix composites 13

14079 Workpiece temperature modelling in CGI drilling process in dry condition 14

14081 Machining modeling, using SPH methodology 15

Session 3: Chatter modeling and suppresion/chairman: Prof. Bleicher

14078 Investigation of hexapod robot dynamics and its effects in milling 16

14044 Chatter suppression in a high speed magnetic spindle by adding damping 17

14050 A method of identification of complex cutting forces acting in unstable cutting process 18

Session 4: High speed machining/chairman: Prof. Abele

14029 High speed machining of profiled grooves in nickel-based alloys 19

14076 Analysis and measurement of cutting temperature in high speed machining of aluminum alloy 20

14071 High speed gear hobbing with cemented carbide hobs 21

Session 5: Chatter modeling and suppresion/chairman: Dr. Munoa

14012 Analytical time-domain model for tool point dynamics in turning 22

14034 Optimal control laws for chatter suppression using inertial actuator in milling processes 23

14013 Integration of machining mechanistic models into CAM software 24

Session 6: Cutting tool design/chairman: Prof. D'Acunto

14053 Derivation of recommendations for the manufacturing of high-speed reaming tools 25

14084 Cutting tool development for effective milling of Ti6Al4V 26

14090 Material specific cutting edge geometries for machining processes 27

Session 7: Cutting fluids/chairman: Dr. Zeman

14011 Turbine blade machining by use of carbon dioxide as cryogenics 28

14035 The influence of high-pressure lubricoolant supply variant on cutting performance in turning of 42CrMo4+QT 29

14065 An experimental investigation of friction and cutting mechanics under the MQL and MQL+CO2 conditions 30

14080 Evaluation of carbide tool performanced under conventional coolant and alternative minimal quantity lubricationin high speed turning Ti-6Al-4V ELI

31

Session 8: Micromachinig/chairman: Prof. He

14031 Experimental investigation in micro-ball-end milling of hardened steel 32

14033 Investigation on micromilling of EBM Ti6Al4V titanium alloy 33

14045 Study of elementary micro-cutting in hardened tool steel 34

14051 Study of burr formation and phase transformation during micro-milling of NiTi alloys 35


Session 9: Tool path planning/chairman: Dr. Sulitka

14039 2D tool-path generation method for multi-axis milling machine using TOF camera 36

14041 Parameters set-up for collision avoidance and smooth motion in 5-axis end milling based on a potential field approach 37

14042 Feedrate optimization in 5-axis machining based on direct trajectory interpolation on the surface using an open CNC 38

14085 A new algorithm for smooth and efficient morphing-based planar tool path generation 39

Session 10: Machining analysis & optimization/chairman: Prof. Niesłony

14016 Wear study and performance evaluation in the machining of MMC with PCD and PCDN tools 40

14017 Comparison of machining inconel 718 with conventional and sustainable coolant 41

14073 Characterization of the cutting phenomenon in orbital drilling of titanium alloys (TiAl6V4) 42

14074 Study of tangential force exerted on rake face during high-speed end milling of Inconel 718 43

Session 11: Machine tool components/chairman: Prof. Jedrzejewski

14038 Dynamic modelling of an electro–hydraulic actuator to isolate machine tools from ground vibrations 44

14040 Damping in linear guides considering operational factors 45

14036 A new device for spindle accuracy inspection 46

14082 Study on vibration response of high-speed spindle with bearing defects 47

Session 12: Machining analysis & optimization/chairman: Prof. Jiang

14018 Velocity measurement of chips at the gun drilling process with an optical measurement systém 48

14022 Phenomenological investigations of heat sources and boundary conditions for metal cutting processes 49

14046 Prediction and compensation of process induced shape deviations in multi-axis high-speed hard finish milling 50

Session 13: Machine tool design/chairman: Dr. Kolář

14014 CNC data acquisition: system development and validation 51

14024 Integration of discontinuous milling operations into the flow production of sheet metal profiles 52

14070 Development of forced cooling using mist of strong alkaline water for restraining thermal deformation on a machine tool 53

Poster session

14015 Heat flux modeling during the machining operations of an explosive material – application to drilling 54

14025 Trajectories in laser machining ceramics: Thermal model to control material removal rate 55

14027 Monitoring of cutting process in end milling of hard and brittle materials 56

14030 Investigation on minimization of chatter vibration in thin-wall machining of Al7075-T651 57

14037 Time domain criteria for controller parameterization by simulation based optimization 58

14043 Analysis of machining configurations with ball-end mills in order to finish parts made by EBM and comparisonwith numerical model

59

14054 сBN-based cutting tools for high-speed cutting of hardened steel and cast iron grades 60

14055 Optimization of design, processing, and cutting performance diagnostics of the cutting inserts based on ceramic composite materials

61

14060 HiPIMS coated carbides with high adhesive strength for hard machining 62

14064 Real time chatter vibration control system in high speed milling 63

14068 Experimental study in plunge milling of damage-tolerant titanium alloy TC21 64

14088 Both-side drive of a ball screw feed axis – verification of the theoretical assumptions 65

INDEX 66

COMMITTEES OF HSM 2014 67


KEYNOTE PAPER

TRENDS IN MACHINE TOOL DESIGN AND USE

M. F. Zäh1*, J. Loehe1

1TUM, TECHNISCHE UNIVERSITAET MUENCHEN, MUNICH, GERMANY (IWB, INSTITUTE OF MACHINE TOOLS AND INDUSTRIAL MANAGEMENT)

*Corresponding author; e-mail: [email protected]

ABSTRACTLooking at modern machine tools, they appear not to have changed significantly. There are new approaches such as parallel kinematics and robots replacing classical machine tools in some applications, but generally spoken the serial mechanical design of machine tools is still widely used. The technological development manifests itself in changes more in detail. Modern machine tools shape a platform for hybrid processes, they allow the shortening of

[Bonin 2011] Bonin, T., Soppa, A., Saak, J., Zaeh, M. F., Faßbender, H., Benner, P. Moderne Modellordnungsreduktionsverfahren für Finite-Ele-mente-Modelle zur Simulation von Werkzeugmaschinen. In: Bertram, T. et al. (ed. ): VDI-Mechatroniktagung 2011. Dresden: 31. 03. -01. 04. 2011, pp. 333-338. [Großmann 2010] Großmann, K., Rudolph, H., Brecher, C., Fey, M., Zaeh, M. F., Niehues, K., Schwarz, S. Dämpfungseffekte in Werkzeugmaschinen – Zielstellung und Vorgehensweise des Forschungsvorhabens. ZWF Zeit-schrift für wirtschaftlichen Fabrikbetrieb 105 (2010) 7-8, pp. 2-6. [Kolkwitz 2012] Kolkwitz, B., Foeckerer, T., Heinzel, C., Zaeh, M. F., Brinks-meier, E. Experimental and Numerical Analysis of the Surface Integrity re-sulting from Outer-Diameter Grind-Hardening. In: Brinksmeier, E. et al. (ed. ): Proceedings of the first CIRP Converence on Surface Integrity (CSI) 2011. Bremen, 30. 01. -01. 02. 2012, pp. 222-227. [Roesch 2013] Roesch, O. Model-based on-line compensation of path de-viations for milling robots. Advanced Materials Research 769 (2013), pp. 255-262

Machine tools; design; trendsKEYWORDS

REFERENCES

process chains, they are advanced in terms of their dynamic behavior and damping, they use adaptronic functions, they are thermally stable, they allow for multiple technologies, they are resource efficient and environmentally friendly and they are developed by using sophisticated means of simulation. This paper outlines these trends and uses examples out of the authors´ personal research interests.

[Waibel 2012] Waibel, M. Aktive Zusatzsysteme zur Schwingungsredukti-on an Werkzeugmaschinen. Diss. Technische Universität München (2012). München: Herbert Utz Verlag GmbH 2013. ISBN: 978-3-8316-4250-2. [Zaeh 2010] Zaeh, M. F., Maier, T. Simulation des thermischen Verhaltens von Werkzeugmaschinen. ZWF Zeitschrift für wirtschaftlichen Fabrikbet-rieb 105 (2010) 7-8, pp. 655-659. [Zaeh 2011] Zaeh, M. F., Wiedenmann, R. Systemtechnik zum laserunter-stützten Fräsen. ZWF Zeitschrift für wirtschaftlichen Fabrikbetrieb 106 (2011) 7-8, pp. 506-509. [Zaeh 2012] Zaeh, M. F., Loehe, J. Die Werkzeugmaschine der Zukunft. In: Zaeh, M. F. et al. (ed. ): Leichter schwer zerspanen! München, 23. 10. 2012. München: Herbert Utz Verlag GmbH 2012, pp. 1-20. [Zaeh 2013a] Zaeh, M. F. Die Werkzeugmaschine der Zukunft. Expert-Fo-rum Automatisierung von Werkzeugmaschinen (Automation of machine tools). Gersthofen, 28. 06. 2013[Zaeh 2013b] Zaeh, M. F., Loehe, J. Die Werkzeugmaschine der Zukunft. Werkstatt + Betrieb 146 (2013) 3, pp. 16–19.


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LATEST DEVELOPMENTS ON HIGH SPEED CUTTING MACHINES:IMPROVEMENTS OF ACCURACY, SPEED AND ENLARGEMENT OF AREA OF APPLICATIONO. Gossel1*

1RÖDERS GMBH,SCHEIBENSTR. 6, 29614 SOLTAU, GERMANY


ABSTRACTRöders, one of the leading companies for supplying HSC machines, was founded more than 200 year ago. In the beginning it was focused on production of pewter products. In the 70th of the last century Röders started to produce blow mould for PET bottles. Based on the requirements of the production of these mouldRöders started in the early 90th to develop HSC machines for its own mould production. Basis on the development was the perception that for high speed cutting not only the dynamic has to be on a higher level of dynamic but also the control, its path planning and drive control. Knowing this Röders began to develop next to the design also an own control. This is still a core competence of Röders to develop the machine together with the control and drive control as one package.One core target of Röders’ development is to reach highest accuracies with finest surfaces. For going forward to this aim there had been several details been developed, like the patented vacuum equilibration, spindle length compensation system or tool cleaning device. For highest accuracies on curved surfaces it is important to control the slow-moving axes as accurate as possible. The focal point in this is the in-house-developed 32-kHz servo control. Its clock frequency is crucial. This is vital for minimizing the position deviation, thus achieving increased dynamic path accuracies. Thanks to the high frequency, the control gets feedback on disturbances as soon as possible. This is clearly noticeable already at the surface contours.For jig grinding, Röders now offers three machine designs: the 3- and 5-axis RXU and RXP machining centres based on linear direct drives and roller guides. There is also the 3-axis RHP

High speed cutting; milling; precision; rigidity; automationKEYWORDS

machine concept with hydrostatic guideways in combination with linear motors: The hydrostatic guides reduce friction to a great degree and result in maximum smoothness, since the axes virtually run by themselves thanks to their oil bearings. Due to the machine’s high basis accuracy with the same setup on all these machines HSC milling and jig grinding is possible without any modification of the machine. Another target of Röders’ development is the combination of speed and accuracy with increased roughing capacity. For an optimal result the Quadroguide concept was developed. Here, the Y slide of the RXU portal machining centres was connected with the portal on a large surface via eight additional carriages arranged in a rectangular pattern. All axes were equipped with linear or torque drives, high-resolution optical encoders while the Z axes received an even stiffer, square cross-section and four guide rails along the corner edges. In this way it was possible to improve the rigidity of the machine frames significantly. Specifically, the rigidity of the Z axis is tripled. But next to outstanding performance of the machine the productivity also has to be taken into account. For a lot of application the automation of the whole process including the change of the workpieces is a must. For supporting its customers in a best way Röders developed own automation systems for exchange of workpieces and cutting tools or grinding wheels next to its own job management system. Going a step ahead Roeders develops, again based on the machines high basis accuracy, as solution to produce mould inserts without the usage of any pallet, this system is able to machine all 6 sides of the inserts.


KEYNOTE PAPER

HIGH PERFORMANCE MACHINING OF AEROSPACE PARTS

N. He1*,L. Li1, Y. Yang1, W. Zhao1

1NANJING UNIVERSITY OF AERONAUTICS AND ASTRONAUTICS, NANJING, 210016, CHINA


ABSTRACTWith the development of high performance aerospace vehicles, the machining of aeronautical parts faces new challenge both in difficult-to-cut materials and difficult-to-cut structures, which leads to low machining efficiency, poor surface quality, serious tool wear, component distortion, high energy consumption, polluting emission and high machining cost. The presentation will introduce high performance machining technology aimed high machining quality, high machining efficiency, low machining cost, measurable, controllable and sustainable machining for the aerospace industry. In order to machining with high efficiency, the high speed plunge milling, high feed milling are developed in the high efficiency machining of titanium alloy. The chatter and vibration are the key problem to limit the increasing machining efficiency. A practical idea of critical depth of cut to test stable parameter is introduced. By varying spindle speed and optimizing unequal blade spacing cutter, the critical depth of cut can be increased significantly resulting higher machining efficiency.The high speed cutting has been applied to machining thin-walled aeronautical parts. By establishing static and dynamic model of cutting force, deflection model of thin-walled part, the deflection of thin-walled part during machining process can be analyzed and predicted. Based on the analyzing of machining deflection,

[He 2012] He, N. et al. (ed.) The high speed cutting technology. Shanghai: Shanghai science and Technology Press, 2012. ISBN: 978-7-5478-1082-8[Schulz 2010] Schulz, H., Abele, E., He, N. (ed.) The high speed machining – fundamentals and application. Beijing: Beijing scientific Press, 2010. ISBN: 978-7-03-028352-8[Shi 2013a] Shi, Q. Research on high performance milling of titanium alloy TC21. Doctoral Dissertation of NUAA (2013). [Shi 2012] Shi, Q., Li, L., He, N. et al. Chip formation in high feed milling da-mage-tolerant titanium alloy. The 9th International Conference on High Speed Machining, 2012, Spain.[Shi 2013b] Shi, Q., Yang, Y. F., He, N., et al. Experiment study of tool wear and surface integrity in high speed milling of a new damage-tolerant titani-um alloy. Materials Science Forum, 2013, 723: 177-181. [Shi 2013c] Shi, Q., Li, L., He, N. et al. Experimental study in high speed milling of titanium alloy TC21. The international Journal of Advanced Manu-facturing Technology, 2013, 64: 49-54.[Qi 2011] Qi, B. Y. Research on Cooling/Lubrication Technology of Green Cutting of Titanium Alloy Based on Surface Micro-textured Tool. Doctoral Dissertation of NUAA (2011). [Yang 2010] Yang, Y. F. Study on Prediction and Control Technology of Machining Distortion for Monolithic Components Based on Inner Stress Field. Doctoral Dissertation of NUAA (2010).

High performance machining; high speed cutting; aeronautical part; low stress millingKEYWORDS

REFERENCES

the high speed cutting can optimized to eliminate machining deflection and toobtained satisfied size accuracy. With the high speed cutting technology of thin-walled part, a titanium alloy part with 0.8 mm thickness and 80 mm height can be machined.The overall machining distortions such as bending or warpage of machined part are serious and very difficult to solve problem in the machining of large monolithic aeronautical part. The machining distortion is mainly due to the inner stress and its distribution in the blank coupled with the residual stress on the workpiece surface produced during cutting process. A new idea of low stress milling technology was put forward, in which the inner stress is measured during rough machining, then the profile distortion is analyzed, finally, the machining strategy and parameters are optimized to control the distortion of component. Two kinds of inner stress measurement methods which can be applied in workshop maintaining the integration monolithic part are developed. Therefore, the large monolithic aeronautical parts can be machined in measurable and controllable wayThe cryogenic minimal quantity lubrication (CMQL) technology was developed. The temperature of cutting media can be lowed to –20° to –30°. By increasing machining efficiency and reducing the coolant pollution, CMQL technology makes the machining process sustainable.

[Wang 2010] Wang, T. Y. Simulation and Experimental Study on the Stability in Milling of Thin-Walled Components. Doctoral Dissertation of NUAA(2010).[Wan 2014] Wan, Y. Research on Residual Stress Measurement using Inclined ESPI Device. Master Dissertation of NUAA (2014).[Cao 2014] Cao, D. Y. The Measurement and Research on the Blank of Thin--walled parts. Master Dissertation of NUAA (2014). [Zhang 2013] Zhang, Y. X. Process Research on Control the deformation of Titanium Alloy Thin-wall Parts. Master Dissertation of NUAA (2013).[Liu 2013] Liu, C. C. Numerical Simulation and Experimental Study on Quenching Residual Stress of 7085 Aluminum Alloy. Master Dissertation of NUAA (2013). [Yang 2013] Yang, T. The Simulation Technology of Machining Distortion for Components Based on the Stress Management. Master Dissertation of NUAA(2013).[Wang 2012] Wang, L. Experiments and Finite Element Simulation of Titanium Alloy Cutting Process Using Surface Micro-textured Cutting Tool. Master Dissertation of NUAA (2012). [Chen 2010] Chen, L. L. Study on Online Measurement of Blank. Master Dissertation of NUAA (2011). [Wang 2009] Wang, Q. A Study of Suppressing Cutting Chatter with Varying Spindle Speed Based on DSP. Master Dissertation of NUAA (2009).


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KEYNOTE PAPER

IMPROVEMENT OF DIE CASTING LIFE TIME BY MACHINE HAMMER PEENING

F. Bleicher1*, C. Lechner1, M. Obermair1, S. Krall1

1INSTITUTE FOR PRODUCTION ENGINEERING AND LASER TECHNOLOGY, VIENNA UNIVERSITY OF TECHNOLOGY, VIENNA, AUSTRIA


ABSTRACTThe functional performance of a component is heavily influenced by the properties of its surface and the metallurgical and mechanical state of the subsurface layers. Therefore the use of novel and innovative surface treatment technologies becomes a key factor in modern tool and mold making industry. The technology of machine hammer peening (MHP) represents such a surface treatment with a

[Adjassoho 2012] Adjassoho, B., Kozeschnik, E., Lechner, C., Bleicher, F., Go-essinger, S. and Bauer, C. Induction of residual stresses and increase of sur-face hardness by machine hammer peening technology. Annals of DAAAM for 2012 & Proceeding of the 23rd International DAAAM Symposium, 2012, Vol. 23, No. 1, pp 697-703. [Bleicher 2012] Bleicher, F., Lechner, C., Habersohn, C., Kozeschnik E., Adjasso-ho, B. and Kaminski, H. Mechanism of surface modification using machine ha-mmer peening technology. CIRP Annals-Manufacturing Technology, 2012, Vol. 61, No. 1, pp 375-378. [Bleicher 2013] Bleicher, F., Lechner, C., Habersohn, C., Obermair, M., Heindl, F. and Rodriguez Ripoll, M. Improving the tribological characteristics of tool and mould surfaces by machine hammer peening. CIRP Annals Ma-nufacturing Technology, 2013, Vol. 62, No. 1, pp 239-242. [Gössinger 2012] Gössinger, S., Bauer, C., Lechner, C. and Bleicher, F. Using machine hammer peening to realize defined surface structures in order to

Machine hammer peening; surface treatment; tool life timeKEYWORDS

REFERENCES

far-reaching technological potential in terms of increasing the surface hardness, influencing the surface topography and generating near-surface compressive residual stresses. Together with the possibilities of mechanical embedding of coating materials and defined surface structuring, the technology offers new possibilities to improve the life time of treated tools and molds.

reduce friction and turbulent fluid flows. 17th Intern. Seminar on Hydropo-wer Plants – Pumped Storage in the Context of Renewable Energy Supply, 2012, Vol. 17, pp 379-388. [Groche 2012] Groche, P., Engels, M., Steitz, M., Müller, C., Scheil, J. and Heilme-ier, M. Potential of mechanical surface treatment for mould and die production. International Journal of Materials Research, 2012, Vol. 103, pp 783-789. [Lechner 2012] Lechner, C., Bleicher, F., Habersohn, C., Bauer, C. and Gössinger, S. The use of machine hammer peening technology for smo-othening and structuring of surfaces. Annals of DAAAM for 2012 & Pro-ceeding of the 23rd International DAAAM Symposium, 2012, Vol. 23, No. 1, pp 331-337. [Lechner 2014] Lechner C. Oberflächenmodifikation unter Einsatz der Technologie des Schlagverdichtens (Machine Hammer Peenings). PHD Thesis, Vienna: University of Technology, Institute for Production Enginee-ring and Laser Technology, 2014.


HSM2014–14061

STIFFNESS IMPROVEMENTS IN COMPLEX PORTABLE MACHINE STRUCTURES BY MEANS OF TOPOLOGY OPTIMIZATION

L. Uriarte1*, J. Eguia1, A. Fernandez1

1IK4 – TEKNIKER, MECHANICAL ENGINEERING UNIT, EIBAR, SPAIN


ABSTRACTSerial kinematics are not particularly favoured as structural solutions for portable machines, since since their stiffness/wieght ratio is notably lower than that coming from parallel kinematics. When countering this fact, is is difficult that a machine tool designer can effectively implement changes in the design towards a maximum stiffness weight ratio without computer based support tools. This work reports on the the application of established topology optimization method on the structure of a challenging portable machine with serial kinematics, aiming at maximizing stiffness-weight ratio and achieving homogeneous stiffness figures in the different axes. Topology optimization is done as dictated by the Solid Isotropic Material with Penalization method (SIMP) running on an interconnected MSC/Nastran-Hyperworks-

Paper in a journal: [Allen 2010] Allen, J., Axinte, D., Roberts, P. A review of recent developments in the design of special-purpose machine tools with a view to identification of solutions for portable in situ-machining systems, Int. J. Adv. Manuf. Tech-nol. (2010) 50: 843-857. [Gonzalo 2010] Gonzalo, O., Beristain, J., Jauregi, H., Sanz, C. A method for the identification of the specific force coefficients for mechanistic milling si-mulation, International Journal of Machine Tools and Manufacture, Volume 50, Issue 9, September 2010, Pages 765-774. [Wang 2004] Wang, L. Basu, P. K., Leiva, J. P. Automobile body reinforcement by finite element optimization. Finite Elements in Analysis and Design 40, 2004, 879-893. [Möhring 2009] Möhring, H. -C. Fast reacting maintenance of forming tools with a transportable machining unit, CIRP Annals – Manufacturing Techno-logy 58 (2009) 359–362. [Shneor 2010] Shneor Y, Portman V (2010), Stiffness of 5-Axis Machines with Serial, Parallel and Hybrid Kinematics, Annals of CIRP 59(1): 409–412. [Tlusty 1999] Tlusty, J., Ziegert, C., Ridgeway, S. (1999) Fundamental Compa-rison of the Use of Serial and Parallel Kinematics for Machines Tools, Annals of CIRP, 48(1): 351–356. [Uriarte 2013] Uriarte, L., Zatarain, M., Axinte, D., Yagüe-Fabra, J., Ihlenfeldt, S., Eguia, J., Olarra, A. Machine tools for large parts. CIRP Annals Manufactu-ring Technology, Volume 62, Issue 2, 2013, Pages 731–750, ISSN: 0007-8506. [Weck 2002] Weck, M.,bStaimer, D. Parallel Kinematic Machine Tools – Cu-

Portable machines; optimization; serial kinematics; SIMP methodKEYWORDS

REFERENCES

Optistruct FEM package. In other words, the optimization process is coupled to the FEM package so that the results can be assessed instantly. Finally, The improvements due to this optimization process are quantified employing FEM calculations, and results are discussed, especially concerning their accuracy and the deviations expected in the physical prototype. The application concludes that topology optimization leads to portable machine structures with stiffness values above 10 N/μm in all XYZ axes, thus above the lower end values of the usual stiffness range of conventional machines, but showing structure weights lower than 1 Tn. However, results also show that the constraints introduced by manufacturability of structures and limits of the technologies used do have an impact on the optimization exercise.

rrent State and Future Potentials, CIRP Annals – Manufacturing Technology-Volume 51, Issue 2, 2002, Pages 671–683. [Kang 2009] Kang, Z., Wang, X., Wang, R. Topology optimization of space ve-hicle structures considering attitude control effort. Finite Elements in Analy-sis and Design, 45 (2009) 431 – 438. [Pessi 2007] Pessi, P., Wu, H., Handroos, H., Jones, L. A mobile robot with pa-rallel kinematics to meet the requirements for assembling and machining the ITER vacuum vessel, Fusion Engineering and Design 82 (2007) 2047–2054. [Wu 2011] Wu, H., Handroos, H., Pela, P., Wang, Y. IWR-solution for the ITER vacuum vessel assembly, Fusion Engineering and Design 86 (2011) 1834–1837. [Li 2011] Li, M., Wu, H., Handroos, H. Static stiffness modeling of a novel hybrid redundant robot machine, Fusion Engineering and Design 86 (2011) 1838–1842.

Paper in proceedings: [Collado 2009] Collado, V., Saenz, A., Gonzalez, J., Astorga, J. "ROPTALMU – A New Concept of Crawling Portable Robotic System for Wing Spars Dri-lling, " SAE Technical Paper 2009-01-3158, 2009, doi: 10. 4271/2009-01-3158.

Technical reports or thesis: [Norberg] Norberg, E., Lövgren, S. Topology Optimization of Vehicle Body Structure for improved Ride & Handling, ExamensarbeteIntitutionenföreko-nomiskochindustriellutveckling. ISRNLUI-IEI-TEK-A—11/01158-SE, http://liu.diva-portal.org/smash/get/diva2:443758/FULLTEXT01.pdf


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HSM2014–14089

THE MODELLING OF LIQUID COOLING FOR THE EFFICIENT REDUCTION OF THERMAL ERRORS IN HEAVY DUTY MACHINE TOOLS

J. Jedrzejewski1*, Z. Winiarski1, J. Y. Ha2

1INSTITUTE OF PRODUCTION ENGINEERING AND AUTOMATION, WROCLAW UNIVERSITY OF TECHNOLOGY, POLAND2DOOSAN INFRACORE CORPORATION, CHANGWON, SOUTH KOREA


ABSTRACTThis paper presents the development and the state of the art of machine tool liquid cooling, focusing on the efficient reduction of thermal errors and on increasing thermal stability in operating conditions. The fundamentals of precision cooling modelling for the heat exchange via a coolant flowing in the channels situated in the motor stator, the bearings, the ball screw nut housing and inside the spindle and the ball screw are described and discussed. Moreover,

[Brecher 2012] Brecher, C., Bäumler, S., Jasper, D. and Triebs, J. Energy effi-cient cooling systems for machine tools, 19th CIRP International Conference on Life Cycle Engineering, 2012, Berkeley, 239-244. [Buchman 1978] Buchman, K., Jungnickel, G., 1978, Die Wärmeubertragun-gan Be-und Verarbeitungmaschinen (in Polish), PWR Wroclaw, ITMiA, 20, 279. [Chien 2008] Chien, C. H. and Jang, J. Y. 3-D numerical and experimental ana-lysis of a built-in motorized high-speed spindle with helical water cooling cha-nnel, Applied Thermal Engineering, 2008, 28, 2327-2336. [Choi 2006] Choi, D. B., Kim, S. T., Jeong, D. S., Lee, J. J. and Kim, Y. K. Ther-mal displacement reduction for the high speed spindle by the internal shaft cooling, Journal of Machine Engineering, 2006, 6/2, 84-96. [Choi 2008] Choi, D. B., Lee, J. J., Kim, S. T., Kwon, H. D. and Kim, C. Y. An ana-lysis on the thermal characteristics according to the viscosity of bearing lub-ricant and the cooling condition for the high speed motor spindle, Journal of Machine Engineering, 2008, 8/4, 88-98. [Donmez 2007] Donmez, M. A., Hahn, M. H. and Soons, J. A. A novel cooling system to reduce thermally-induced errors of machine tools, Annals of the CIRP, 2007, 56/1, 521-524. [Ganes 2012] Ganesh, Madhan Muthu K., Kamalesh, N. V., Dawood Shaik, A. K. and Karthikeyan, M. CFD Analysis of cooling channels in built-in motorized high speed spindle. IRACST – Engineering Science and Technology: An Inter-national Journal (ESTIJ), 2012, 2/2, 238-244, ISSN: 2250-3498. [Haas 1975] de Haas P. Moeglichkeiten und Grenzen zur Kompensation- thermischer Stoereinflussen bei Fertigungsystemen. ZwF, 1975, 70/7, 366-370. [Haas 1978] de Haas P. and Heisel U. Kompensationthermischer Deformatio-nenan Werzeugmaschinen. ZwF, 1978, 73/11, 555-560. [Jedrzejewski 1968] Jedrzejewski, J. and Potrykus, J. Die Warmeableitung an Werkzeugmaschinen Spindellagerungen. Maschinenbautechnik, 1968, Jg. 17, H. 8, 423-426, [Jedrzejewski 1972] Jedrzejewski, J., Potrykus, J. and Kwasny, W. Device for heat transfer from bearing nodes of machine tools, Patent (Polish) 1972, No. 64570. [Jedrzejewski 1973] Jedrzejewski, J. Zur Erwaermung von Drehmaschinen – Spindlkasten. Werkzeugmaschinen International, 1973, 4, 47-50. [Jedrzejewski 1985] Jedrzejewski J., 1985, Application of numerical computa-tions to the improvement of the thermal properties of machine tools (in Po-lish), Research Works of the Institute of Production Engineering, Wroclaw University of Technology, Conferences no. 8, 72-92. [Jedrzejewski 1988] Jedrzejewski, J. Directions for improving the thermal sta-bility of machine tools / Thermal aspects in manufacturing, The Winter Annu-al Meeting of the American Society of Mechanical Engineers, Chicago, Illinois, New York, ASME, PED, 1988, 30, 165–182.

Machine tool; cooling; modellingKEYWORDS

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an accurate method of modelling the heat exchange between the cooling-lubricating oil and the gears, the shafts and the walls in high-torque headstocks is presented. The idea of integrating the liquid cooling equations with the in-house FEM SATO system is briefly described. Examples of the modelling and computer simulation of the thermal behaviour of a liquid-cooled heavy duty headstock and of verification by measurements are provided and discussed.

[Jedrzejewski 1989] Jedrzejewski, J., Kwasny, W. and Potrykus J. Beurtei-lung der Berechnungsmethoden fur die Bestimmung der Energieverluste im Walzlagern. Schmierungstechnik, 1989, 20/8, 243-244. [Kowal 1990] Kowal Z., Winiarski Z., 1990, Computer system for the ana-lysis and optimization of the thermal deformations of machining centres (in Polish), Przegląd Mechaniczny, 49, 21/22, 42-46. [Mares 2013] Mares, M., Horejs, O., Hornych, J. and Smolik, J. Robust-ness and portability of machine tool thermal error compensation model based on control of participating thermal sources. Journal of Machine Engineering, 2013, 13/1, 24-36. [Moorthy 2012] Moorthy, S. R., Raja, P. V. and Lakshmipathi, R. Analysis of High Speed Spindle with a Double Helical Cooling Channel, . International Journal of Scientific & Engineering Research, 2012, 3/5, 1-5. [Potrykus 1988] Potrykus, J. and Wojciechowski, T. Die Ol-Luft- Minimal-mengenschmierung und deren A nwendungim Werkzeugmaschinenbau. Schmierungstechnik, 1988, Jg. 19/4, 104–107. [Potrykus 1995] Potrykus, J. Energetische Aspekte der Minimalmengen-schmierunghochtouriger Spindellager, Tribologie und Schmierungstech-nik, 1995, Jg 42/5, 255-259. [Weber 2013] Weber, J. and Weber, Jür. Thermo-energetic analysis and simulation of the fluidic cooling system of motorized high-speed spin-dles, The 13th Scandinavian International Conference on Fluid Power, SICFP2013, June 3-5, 2013, Linköping, Sweden, 131–140. [Winiarski 2006a] Winiarski, Z. and Kowal, Z. Investigation of the effects of heat generation in HSM electroheadstocks, Journal of Machine Engi-neering, 2006, 6/2, 107–115. [Winiarski 2006b] Winiarski Z., 2006, Thermal analyses in the design of elecrospindles for modern machine tools (in Polish), Mechanik, 03, SIMP, Warsaw, 230-234. [Winiarski 2008] Winiarski, Z., Kowal, Z. and Blazejewski, A. Decreasing of thermal errors in a lathe by forced cooling of ball screws and headstock, Journal of Machine Engineering, 2008, 8/4, 122–130[Winiarski 2010] Winiarski, Z., Kowal, Z., Kwasny, W. and Ha, J-Y. Ther-mal model of the spindle drive structure, . Journal of Machine Enginee-ring, 2010, 10/4, 41-52. [Xirouchakis 2009] Xirouchakis, P., Avram, O. I. and Adham, M. Machine tool cooling and lubrication in the use phase. Final Report, Swiss Federal Institute of Technology, Lausanne, 17-Jun, 2009, 1-24. [Vyroubal 2010] Vyroubal, J. Using the spindle cooling temperature as a tool for compensating the thermal deformation of machines, ActaPoly-technica, 2010, 50/1, 19-22.


HSM2014–14092

SIMULATION MODEL FOR QUICK PREDICTIONS OF WORKPIECE DYNAMIC RESPONSE IN MACHINING

J. Šindler1*, M. Sulitka1, R. Ur-Rehman2, C. Richterich3, A. Schäfer2

1CZECH TECHNICAL UNIVERSITY IN PRAGUE, FACULTY OF MECHANICAL ENGINEERING, RCMT, PRAGUE, CZECH REPUBLIC2FRAUNHOFER INSTITUTE FOR PRODUCTION TECHNOLOGY IPT, AACHEN, GERMANY3MODULEWORKS GMBH, AACHEN, GERMANY


ABSTRACTMachining of lightweight components represents nowadays one of the technology challenges. Low static and dynamic stiffness of thin wall work pieces lead to significant problems during the milling process with respect to static deflections and vibration of both the work piece and tool induced by exciting the tool and work piece system by process forces. In the praxis, finding the appropriate cutting parameters ensuring a stable cut and an acceptable surface quality, precision and time of machining, usually results from a number of trial and error testing. During material removal the work piece dynamics is continuously changing, which limits setting of the cutting parameters by the most compliant case. To overcome those problems and to effectively optimize machining of thin walled work pieces, a CAM planning module is being developed within the EU funded project DynaMill. The module covers tool path planning module, tool path simulation with consequent material removal calculation, calculation of the work piece dynamics and process simulation with the prediction of process forces. The paper introduces a new time efficient simulation approach for predicting the work piece dynamics during machining. The strategy is based on expressing the response function of the

[Alan 2010] Alan, S., Budak, E., and Özgüven, H. N. 2010. Analytical Predic-tion of Part Dynamics for Machining Stability Analysis. International Jour-nal of Automation Technology. 4, pp. 259-267. [Atlar 2008] Atlar, S., Budak, E., and Özgüven, H. N. 2008. Modeling Part Dynamics and Chatter Stability In Machining Considering Material Remo-val. In: Proceedings of the 1st CIRP International Conference on Process Machine Interactions. [Avitabile 2003] Avitabile, P. 2003. Twenty Years of Structural Modification, A Review. Journal of Sound and Vibration. 37, pp. 14-27.

Work piece dynamics; machining simulation; material removal; vibrationKEYWORDS

REFERENCES

work piece initial finite element (FE) model by multivariate Pade approximation, which is parametrized by the element virtual densities. The virtual densities are used for identifying the elements to be virtualy removed, or kept in the model by means of the STL models of the material removed. Once the clamping of the work piece does not change during machining, one Pade approxamation is enough for simulating any material removal. The proposed method is therefore very time efficient, the calculation of eigenmodes takes just fractions of second. The technique is enhanced also by the possibility of morphing the initial FE mesh, which can be intersected with the work piece preform to simulate machining of any work piece shape. This makes the strategy fully independent from any finite element SW environment and can therefore be implemented in the CAM planning module being developed. The simulation model is tested using simple plate work piece and a real turbine blade, showing very high precision. The proposed method fulfills the requirements defined in the DynaMill project and can therefore very efficiently serve for quick optimizing the tool path and cutting conditions taking into account the workpiece varying static and dynamic responsse during machining.

[Budak 2012] Budak, E.,Taner Tunc, L., Alan, S. and Özgüven, H. N. 2012. Prediction of workpiece dynamics and its effects on chatter stability in mi-lling. CIRP Annals – Manufacturing Technology. 61(1), pp. 339-342. [Guillaume 2000] Guillaume, P. and Huard, A. 2000. Multivariate Padé approximation. Journal of Computational and Applied Mathematics. 121, pp. 197-219. [Özgüven 1990] Özgüven, H. Nevzat. 1990. Structural modifications using frequency response functions. Mechanical Systems and Signal Processing. 4(1), pp. 53-63.


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HSM2014–14052

PREDICTION OF THE SPINDLE AND TOOL RECEPTANCE: INDUSTRIAL APPLICATION IN REAMING PROCESS

J. Selmi1, 3*, J. P. Costes1, P. Lorong2, G. Poulachon1, P. Carras3

1ARTS ET MÉTIERS PARISTECH, LABOMAP, RUE PORTE DE PARIS, CLUNY, FRANCE2ARTS ET MÉTIERS PARISTECH, PIMM, BOULEVARD DE L’HÔPITAL, PARIS, FRANCE3RENAULT, RUE DES BONS RAISINS, RUEIL MALMAISON, FRANCE


ABSTRACTThe choice of machine tool is mainly ruled regarding its power and torque limitations. However, these precautions do not guarantee the process to remain in stable condition. For example, chatter depends on many factors and among others on the machine tool vibrations properties. This particular point is rarely considered during the machining process design. This can be explained by the difficulties to obtain machine tool dynamic properties taking into account the diversity of spindles and tools combinations. The aim of the work presented in this paper is to apply a methodology in order to evaluate the ability of different systems (Spindle –

Paper in a journal: [Abele 2010] Abele, E., Altintas, Y., and Brecher, C. Machine tool spindle units. {CIRP} Annals – Manufacturing Technology, 59(2): 781-802, 2010. [Abele 2004] Abele, E. and Fiedler, U. Creating stability lobe diagrams during milling. {CIRP} Annals – Manufacturing Technology, 53(1): 309-312, 2004. [Altintas 1995] Altintas, Y. and Budak, E. Analytical prediction of stability lo-bes inmilling. CIRP Annals – Manufacturing Technology, 44: 357-362, 1995. [Altintas 2004] Altintas, Y. and Weck, M. Chatter stability of metal cutting and grinding. {CIRP} Annals – Manufacturing Technology, 53(2): 619-642, 2004. [Catania 2011] Catania, G. and Mancinelli, N. Theoretical-experimental modeling of milling machines for the prediction of chatter vibration. Inter-national Journal of Machine Tools and Manufacture, 51(4): 339-348, 2011. [Erturk 2006a] Erturk, A., Ozguven, H. N. and Budak, E. Analytical modeling of spindletoo ldynamics on machine tools using timoshenko beam model and receptance coupling for the prediction of tool point {FRF}. Internatio-nal Journal of Machine Tools and Manufacture, 46(15): 1901-1912, 2006. [Gagnol 2011] Gagnol, V., Thien-Phu Le, and Pascal Ray. Modal identi_cati-on of spindle-tool unit in high-speed machining. Mechanical Systems and Signal Processing, 25(7): 2388-2398, 2011. [Gurney 1961] Gurney, J-P. A graphical method for the determination of the dynamic stability of machine tools, international journal of machine tool design and research. Benstone instruments, 1 : 148-156, 1961. [Jochem 2007] Jochem, C., Roukema and Yusuf Altintas. Generalized mo-deling of drilling vibrations. part ii: Chatter stability in frequency domain. International Journal of Machine Tools and Manufacture, 47(9): 1474-1485, 2007. Selected papers from the 2nd International Conference on High Per-formance Cutting 2nd {CIRP} International Conference on High Performan-ce Cutting. [Namazi 2007] Mehdi Namazi, Yusuf Altintas, Taro Abe, and Nimal Rajapakse. Modeling and identi_cation of tool holder – spindle interface dynamics. Inter-national Journal of Machine Tools and Manufacture, 47(9): 1333-1341, 2007. Selected papers from the 2nd International Conference on High Performance Cutting 2nd {CIRP} International Conference on High Performance Cutting. [Ozsahin 2009] Ozsahin, O., Erturk, A., Ozguven, H. N. and Budak, E. A clo-

Spindle; tool; chatter; stability; reaming; receptance couplingKEYWORDS

REFERENCES

Tool) to run a reaming process in a stable way. The proposed methodology is based on an experimental measurement of the dynamic behavior for the system including the spindle and the tool holder. Then, by coupling frequencies response functions, a new system (Spindle –Tool) FRF is predicted at the tool tip. Finally, in order to compare different systems (Spindle –Tool), the critical depth of cut is analytically calculated from the eigenvalues of the characteristic equation of the dynamic reaming process in the frequency domain. The system that allows the highest material removal rate is considered as the best.

sed-form approach for identi_cation of dynamical contact parameters in spindleholder-tool assemblies. International Journal of Machine Tools and Manufacture, 49(1): 25-35, 2009. [Peklenik 1967] Peklenik, J. and Gartner, J. R. Workpiece accuracy criteri-on for the dynamic machine tool acceptance test. International Journal of Machine Tool Design and Research, 7(4): 303-324, 1967. [Sadek 1970] Sadek, M. M. and Tobias, S. A. Comparative dynamic acceptan-ce tests for machine tools applied to horizontal milling machines. Procee-dings of the Institution of Mechanical Engineers, 185(1): 319-337, 1970. [Tobias 1962] Tobias, S. A. Dynamic acceptance tests for machine tools. In-ternational Journal of Machine Tool Design and Research, 2 : 267-280, 1962. [Tobias 1965] Tobias, S. A. Machine tool vibration. Blackies and Son, London, 1965. [Wang 1996] Wang, J. H. Suppression of chatter vibration of a cnc machine center an exemple. Mechanical Systems and Signal Processing, 10: 551-560, 1996. [Yuce 1983] Yuce, M. Pulse excitation technique for determining frequency response of machine tools using an on-line minicomputer and a non-con-tacting electromagnetic exciter. International Journal of Machine Tool De-sign and Research, 23: 39-51, 1983.

Paper in proceedings: [Tlusty 1954] Tlusty, J. and Spacek, L. R. Self-excited vibrations on ma-chine tools. Publication of the Czech Academy of Sciences (Nakl. CSAV in Czech), 1954. Technical reports or thesis: [Erturk 2006b] Erturk, A. Dynamic modeling of spindle – tool assemblies in machining centers. PhD thesis, 2006. [Gagnol 2006] Gagnol, V. Modelisation du comportement dynamique des electrobroches UGV. PhD thesis, 2006. [Koppka 2008] Koppka, F. A contribution to maximization of productivity and workpiece quality of the reaming process by analyzing its static and dy-namic behavior, PhD thesis, Darmstadt, December 2008 [Pruvot 1995] Pruvot, F. Conception et calcul des machines-outil. Benstone instruments, 3 : 344 pages, 1995.


HSM2014–14019

COUPLED EULERIAN-LAGRANGIAN MODELLING OF HIGH SPEED METAL CUTTING PROCESSES

F. Klocke1, D. Lung1, H. Puls1*

1WZL, LABORATORY FOR MACHINE TOOLS AND PRODUCTION ENGINEERING, RWTH AACHEN UNIVERSITY, AACHEN, GERMANY


ABSTRACTThe further development of metal cutting requires extended knowledge about the thermo-mechanical phenomena occurring within the process. Due to the limited spatial and temporal resolution of common measurement equipment, this knowledge can be hardly obtained by experimental studies. In addition, it is not possible to measure interesting quantities as stresses and strains for the process optimization. To resolve these issues, modelling approaches are subject to many current research projects. This paper presents and discusses a new technique to simulate

[Abouridouane 2012] Abouridouane, M., Klocke, F., Lung D., Adams, O.: A new 3D multiphase FE model for micro cutting ferritic-pearlitic carbon ste-els, CIRP Ann-Manuf. Techn., 2012, Vol. 61, pp. 71-74[Arrazola 2009] Arrazola, P. J., Arriola, I., Davies, M.: Analysis of the influence of tool type, coatings, and machinability on the thermal fields in orthogonal ma-chining of AISI 4140 steels. CIRP Ann-Manuf Techn., 2009, Vol. 58, pp. 85-88[Arrazola 2013] Arrazola, P. J., Özel, T., Umbrello, D., Davies, M., Jawahir, I. S.: Recent advances in modelling of metal machining processes, CIRP Ann--Manuf Techn, 2013, Vol. 62, No. 2, pp. 695-718[Beiss 2002] Beiss, P., Ruthhardt, R., Warlimont, H.: Powder Metallurgy Data. Refractory, Hard and Intermetallic Materials. Landolt-Börnstein – Group VIII Advanced Materials and Technologies, 2002, Springer, Berlin/Heidelberg. [Benson 1992] Benson, D. J.: Computational methods in Lagrangian and Eu-lerian hydrocodes. Computer Methods in Applied Mechanics and Enginee-ring, 1992, Vol. 99, 1992, pp. 235-394[Benson 2004] Benson, D. J., Okazawa, S.: Contact in a multi-material Eu-lerian finite element formulation. Computer Methods in Applied Mechanics and Engineering, 2004, Vol. 193, No. 39-41, pp. 4277-4298[Brookes 1992] Brookes, K. J. A.: World Directory and Handbook of Hard me-tals and Hard Materials, 5th Edition, International Carbide Data, Hertfordshire. [Courbon 2013] Courbon, C., Mabrouki, T., Rech, J., Mazuyer, D., D'Eramo, E.: On the existence of a thermal contact resistance at the tool-chip interface in

Coupled eulerian-lagrangian modelling; chip formation simulation; FEM; CELKEYWORDS

REFERENCES

the chip formation process which couples the Lagrangian and Eulerian finite element discretization of the workpiece and tool. The technique provides significant advantages but also some disadvantages compared to commonly used methods. The capabilities are analyzed within a 3D external turning multiphysics model with special focus on the computational efforts which decrease with increasing cutting speed due to the explicit time integration. Therefore the method is especially efficient for simulating high speed machining processes.

dry cutting of AISI 1045: Formation mechanisms and influence on the cutting process. Applied Thermal Engineering, 2013, Vol. 50, No. 1, pp. 1311–1325[Dassault 2014] Dassault Systèmes: ABAQUS Analysis, User’s Guide 6. 13-4, 2014[Johnson 1983] Johnson, G. R.; Cook, W. H.: A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. In: Proceedings of the 7th Int. Symposium on Ballistics, 1983, pp. 541-547[Klocke et al. 2013] Klocke, F., Lung, D., Buchkremer, S.: Inverse Identificati-on of the Constitutive Equation of Inconel 718 and AISI 1045 from FE Machi-ning Simulations. Procedia CIRP, 2013, Vol. 8, pp. 212-217[Klocke et al. 2013b] Klocke, F. Lung, D., Puls, H.: FEM-Modelling of the Thermal Workpiece Deformation in Dry Turning, Procedia CIRP, Vol. 8, 2013, pp. 240-245[Martan 2012] Martan, J., Beneš, P.: Thermal properties of cutting tool coatings at high temperatures. Thermo-chemica Acta, 2012, Vol. 539, pp. 51-55[Puls et al. 2014] Puls, H., Klocke, F., Lung, D.: Experimental investigation on friction under metal cutting conditions. Wear, 2014, Vol. 310, No. 1-2, pp. 63-71[Spittel 2009] Spittel, M., Spittel, T.: Steel symbol/number: C45/1. 0503. War-limont, H. ed. SpringerMaterials – The Landolt-Börnstein Database, Springer, Berlin/Heidelberg DOI: 10. 1007/978-3-540-44760-3_26[Uhlmann et al. 2007] Uhlmann, E., Graf von der Schulenburg, M., Zettier, R.: Finite element modeling and cutting simulation of Inconel 718. Annals of the CIRP, 2007, Vol. 56, No. 1, pp. 61-64


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HSM2014–14020

FINITE ELEMENT MODELING OF THE ORTHOGONAL MACHINING OF PARTICLE REINFORCED ALUMINUM BASED METAL MATRIX COMPOSITES U. Umer1*, A. M. Yusuff1, J. A. Qudeiri1, A. R. Al-Ahmari1

1FARCAMT, ADVANCED MANUFACTURING INSTITUTE, KING SAUD UNIVERSITY, RIYADH 11421, SAUDI ARABIA


ABSTRACT2D finite element models (FEM) are developed to simulate orthogonal machining of particle reinforced aluminum based metal matrix composites (MMC). The models predict cutting forces, chip morphology, temperatures and stresses distribution in the cutting tool and workpiece. The effect of different process parameters like cutting speed, feed rate and rake angle has been simulated by developing a fully coupled temperature displacement model. In contrast to the equivalent homogeneous material (EHM) methodology, a heterogeneous model is developed based on reinforcement particle size and volume fraction. This allows models to simulate the local effects such as tool-reinforcement

[Abaqus 2012] ABAQUS Documentation. Dassault Systemes, 2012.[Arola 1997] Arola, D., Ramulu, M. Orthogonal cutting of fiber-reinforced composites: a finite element analysis. Int J Mech Sci,1997 39(5), 597–613[Camus 2000] Camus, G. Modelling of the mechanical behavior and damage processes of fibrous ceramic matrix composites: application to a 2D SiC/SiC. International Journal of Solids and Structures, 2000, 37(6), 919-942[Chawla 2006] Chawla, N. and Chawla, K. Metal Matrix Composites, 2006[Dandekar 2009] Dandekar, C. R., Shin, Y. C. Multi-step 3D finite element modeling of subsurface damage in machining particulate reinforced metal matrix composites. Composites Part A: Appl Sci Manuf., 2009 40(8), 1231–1239[Dandekar 2010] Dandekar, C. R. Multi-Scale Modelling and Laser-Assisted Machining of Metal Matrix Composites. Indiana: Purdue University, 2010[Davim 2011] Davim, J. P. Machining of Metal Matrix Composites, 2011[El-Gallab 1998] El-Gallab, M., Sklad, M. Machining of Al/SiC particulate metal-matrix composites. Part I: Tool performance. J Mater Process Tech, 1998, 83(1–3), 151–158[El-Gallab 2004] El-Gallab, M. S., Sklad, M. P. Machining of aluminum/silicon carbide particulate metal matrix composites. Part IV: Residual stresses in the machined workpiece. J Mater Process Tech., 2004, 152(1), 23–34[Fathipour 2012] Fathipour et al. Investigation of Reinforced Sic Particles Percentage on Machining Force of Metal Matrix Composite. Modern Applied Science, 2012,6(8), 9-20[Looney 1992] Looney, L. A. et al. The turning of an Al/SiC metal matrix com-posites. Journal of Materials Processing Technology, 1992, 33(4), 453-468[Manna 2003] Manna, A., Bhattacharyya, B. A study on machinability of Al/SiC-MMC. J Mater Process Tech.,2003, 140(1–3),711–716

Finite Element Models (FEM); Metal Matrix Composites (MMC); Cohesive Zone Modeling (CZM)KEYWORDS

REFERENCES

particle interaction, reinforcement particle debonding and subsurface damages to the workpiece. The interface between the reinforcement particles and the matrix is modeled by using two approaches; with and without cohesive zone elements. Similarly the chip separation is modeled with and without using a parting line. The effect of different methodologies on the model development, simulation runs and predicted results have been discussed. The results are compared with experimental data and it has been found that the utilization of cohesive zone modeling (CZM) with the parting line approach seems to be the best one for the modeling of MMC machining.

[Muthukrishnan 2008] Muthukrishnan, N. et al. An investigation on the Machinability of Al-SiC metal matrix composites using PCD inserts. Inter-national Journal of Advanced Manufacturing Technology, Spring Verlag, 2008, 38, 447-454.[Monaghan 1998] Monaghan, J., Brazil, D. Modelling the flow processes of a particle reinforced metal matrix composite during machining. Composites Part A-Appl S. 1998, 29(1–2), 87–99[Nayak 2005] Nayak, D., Bhatnagar, N., Mahajan, P. Machining studies of ud--frp composites. Part 2: Finite element analysis. Mach. Sci. Technol., 2005, 9, 503–528[Pramanik 2007] Pramanik, A., Zhang, L. C., Arsecularatne, J. A. An FEM in-vestigation into the behviour of metal matrix composites: tool-particle interac-tion during orthogonal cutting. Int. J Mach Tool Manuf., 2007, 47(10), 1497–1506[Quigley 1994] Quigley, O., Monaghan, J., O’Reilly, P. Factors affecting the ma-chinability of an Al/SiC metal-matrix composite. J Mater Process Tech,1994 43(1), 21–36.[Rao 2007] Rao, G. V. G., Mahajan, P., Bhatnagar, N. () Machining of UD-GFRP composites chip formation mechanism. Compos Sci Technol., 2007, 67 (11–12), 2271–2281.[Schwartz 1997] Schwartz, M. M. Composite Materials Fabrication. Processing and applications, 1997[Weinert 1993] Weinert, K., König, W. A consideration of tool wear mechani-sm when machining Metal Matrix Composites (MMC). Ann CIRP, 1993, 42(1), 95–98[Zhu 2005] Zhu, Y. and Kishawy, H. Influence of Alumina particles on machi-ning of MMC. International Journal of Machine tool and manufacture, 2005, 389-398


HSM2014–14079

WORKPIECE TEMPERATURE MODELLING IN CGI DRILLING PROCESS IN DRY CONDITION

A. T. Kuzu1*, K. Rahimzadeh Berenji1, M. Bakkal1

1ISTANBUL TECHNICAL UNIVERSITY, FACULTY OF MECHANICAL ENGINEERING, ISTANBUL, TURKEY


ABSTRACTCompacted graphite iron (CGI) has been increasingly popular in automotive industry as an engine component material because of superior mechanical and physical properties of CGI in comparison with gray cast iron. In spite of these properties, CGI has poor machinability. The engine component material must be economically attainable as well as providing efficient combustion is the inevitable necessity of present-day. An economic production can be only achieved with high machinability. One of the key factors which are affecting machinability is the temperature control on tool and workpiece surfaces. The higher workpiece temperature has negative affect on microstructure and part tolerances. This paper investigates the compacted graphite iron workpiece temperature distribution in drilling process. The cutting forces and torque values have been obtained using segregated cutting edge method at the very beginning of the study. Each segregated cutting edges were named as elementary cutting tool (ECT) due to the different cutting angles on each element. Cutting force distribution on chisel and cutting lip has also been modeled

Paper in a journal: [Altintas 2011] Altintas, Y. Manufacturing Automation. Cambridge: Cam-bridge University Press, 2011. ISBN 978–1–107-00148-0[Armarego 1984] Armarego, E. J. A., and Wright, J. D. Predictive models for drilling thrust and torque—a comparison of three flank configurations. CIRP Annals-Manufacturing Technology, 1984, Vol. 33, Issue 1, pp 5–10. ISSN 0007-8506[Audy 2008] Audy, J. A study of computer-assisted analysis of effects of drill geometry and surface coating on force and power in drilling. journal of mate-rial processing technology, 2008, Vol. 204, Issues 1–3, August 2008, pp 130–138. ISSN 0924-0136[Bono 2001] Bono, Matthew, and Jun Ni. The effects of thermal distortions on the diameter and cylindricity of dry drilled holes. International Journal of Machine Tools & Manufacture, 2001, Vol. 41, Issue 15, December 2001, pp 2261-2270. ISSN 0890-6955[Budak 1996] Budak, E., Armarego, A. J., and Altintas, Y. Prediction of mi-lling force coefficients from orthogonal cutting data. Journal of enginee-ring for industry, Vol. 118, Issue 2, May 1996, pp. 216-224. ISSN 0022-0817[Elhachimi 1999] Elhachimi, M., Serge, T., and Pierre, J. Mechanical mo-delling of high speed drilling. 1: predicting torque and thrust. International Journal of machine tools and Manufacture, Vol. 39, Issue 4, April 1999, pp. 553-568. ISSN 0890-6955. [Elhachimi 1999] Elhachimi, M., Serge, T., and Pierre, J. Mechanical mode-lling of high speed drilling. 2: predicted and experimental results. Interna-

Dry drilling; workpiece temperature distribution; drilling force modelKEYWORDS

REFERENCES

considering the cutting speed and characteristic angle variation at each ECT, which is a function of tool radius. Then cutting forces and torque were used as an input in order to calculate heat flux for each segregated cutting edge. The advection heat partition model, which is developed by Bono and Ni [2002] was applied to obtained heat flux loads. The finite element analysis (FEA) was used to predict temperature distributions on the workpiece. In this model heat flux loads were applied on the shell elements on the top of cutting edge–workpiece contact line. This heat flux was applied on chisel edge and cutting edges. Two of total seven elements of ECT allocated on chisel edge and rest five elements were placed on the cutting edge. Applied heat flux values were average values of total heat loads of each ECTs. During the drilling process, when the drill bit penetrates into the workpiece, the elements were sequentially removed and heat flux applied on the subsequent elements. The developed thermal model was verified by using embedded thermocouples and good agreements obtained between experimen-tal and predicted temperature distribution results.

tional Journal of machine tools and Manufacture, April 1999, Vol. 39, Issue 4, pp 569-581. ISSN 0890-6955, [Kalidas 2002] Kalidas, S., Kapoor, S. G., and DeVor, R. E. Influence of Ther-mal Effects on Hole Quality in Dry Drilling, Part 1: A Thermal Model of Wor-kpiece Temperatures. Journal of Manufacturing Science and Engineering, April 2002, Vol. 124, No 2, pp. 258-266. ISSN1087–1357[Klocke 1997] Klocke, F. and Eisenblätter G. "Dry Cutting." CIRP Annals – Manufacturing Technology, 1997, Vol. 46, No 2, pp 519-526. ISSN 0007-8506 [Pal 1965] Pal, A. K., Bhattacharyya, A., and Sen, G. C. Investigation of the torque in drilling ductile materials, International Journal of Machine Tools Design and Research, June 1965, Vol. 4, No. 4, pp 205-221. ISSN 0020-7357[Tai 2012] Tai, B. L., Stephenson, D. A., and Shih, A. J. An Inverse Heat Transfer Method for Determining Workpiece Temperature in Minimum Quantity Lubrication Deep Hole Drilling. Journal of Manufacturing Science and Engineering, April 2012, Vol. 134, No. 2, ISSN 1087–1357[Watanebe 1977] Watanebe, K., Yokoyuma, K., and Ichimaya, R. Thermal Analyses of the Drilling Process. Journal of the Japan Society of Precision Engineering, 1977, Vol. 11, No. 2., pp 71-77 ISSN 0582-4206.

Paper in proceedings: [Stabler 1951] Stabler, G. V. The Foundational geometry of cutting tool. Pro-ceedings of the Institution of Mechanical Engineers, 1951 pp 14-26


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HSM2014–14081

MACHINING MODELING, USING SPH METHODOLOGY

V. Gyliene1*, M. Ubartas2

1DEPARTMENT OF PRODUCTION ENGINEERING, FACULTY OF MECHANICAL ENGINEERING AND DESIGN, KAUNAS UNIVERSITY OF TECHNOLOGY, KAUNAS, LITHUANIA2FACULTY OF MECHANICAL ENGINEERING AND DESIGN, KAUNAS UNIVERSITY OF TECHNOLOGY, KAUNAS, LITHUANIA


ABSTRACTThe orthogonal turning research is also performed as a scientific challenge. In mesoscale study this turning study is simplified according to the geometry of contacting bodies going in contact. This contact-impact interaction performs the nonlinearities of material, later removed. So, here it is the purpose to simplify the geometries of contacting bodies in the cutting process. But the great variety and complexity of real machining operations leads us not to simplify the cutting process for fundamental understanding. By the example of the orthogonal turning process the “ambiguities” of Finite Element Modeling (FEM) are exposed in the article. Symonds-Cowper material behavior law with kinematic-isotropic hardening was chosen for numerical modeling in this article. Using this material behavior law modeling by FEM, the artificial material destruction criterion as failure strain is needed. Failure criterion could be adjusted or experimentally or empirically. Considering material behavior law, the choice of type of hardening law may influence the results dramatically. Two series of simulations were performed according to material hardening law. Orthogonal turning simulation with kinematic coefficients corresponds correctly (2. 1%) with experimental results. The same results were obtained when using kinematic–isotropic hardening constants. Consequently the another precision of FE model is needed. And the chip form can be second parameter for the precision of composed

[Poulachon 2001] Poulachon, G., Moisan, A. and Jawahir, I. S. On Modelling the Influence of Thermo-Mechanical Behavior in Chip Formation During Hard Tur-ning of 100Cr6 Bearing Steel. CIRP Annals. Manufacturing. Technology, 2001, Vol. 50, No. 1., p. 31–36. [Van Luttervelt 1998] Van Luttervelt, C. A. et al. Present Situation and Futu-re Trends in Modelling of Machining Operations Progress Report of the CIRP Working Group Modelling of Machining Operations. CIRP Annals. Manuf. Tech-nol., 1998, Vol. 47, No. 2., p. 587–626. [Arrazola 2013] Arrazola et al. Recent Advances in Modelling of Metal Machi-ning Processes. CIRP Ann. – Manuf. Technol., 2013, Vol. 62, No. 2., p. 695–718. [Ding 2013] Ding, H. and Shin, Y. C. Multi-physics Modeling and Simulations of Surface Microstructure Alteration in Hard Turning. J. Mater. Process. Technol., June 2013, Vol. 213, No. 6., p. 877–886. [Umbrello 2007] Umbrello, D., M’Saoubi, R. and Outeiro, J. C. The Influ-ence of Johnson–Cook Material Constants on Finite Element Simulation of Machining of AISI 316L steel. Int. J. Mach. Tools Manuf., Mars 2007, Vol. 47, No. 3–4, p. 462–470. [Xie 1996] Xie, J. Q., Bayoumi, A. E. and Zbib, H. M. A Study on Shear Banding in Chip Formation of Orthogonal Machining. Int. J. Mach. Tools Manuf., 1996, Vol. 36, No. 7, p. 835–847. [Kaymakci 2012]. Kaymakci, M., Kilic, Z. M. and Altintas, Y. Unified Cutting For-ce Model for Turning, Boring, Drilling and Milling Operations. Int. J. Mach. Tools Manuf., Mars 2012, Vol. 54–55, p. 34–45. [Gyliene 2012] Gyliene, V. and Ostasevicius, V. Modeling and Simulation of a Chip Load Acting on a Single Milling Tool Insert. Strojniski Vestn. – J. Mech. Eng., December 2012, vol. 58, No. 12, p. 716–723.

Orthogonal turning; drilling; FEM; SPH; LS-DYNAKEYWORDS

REFERENCES

FE model. The choice of dynamic constants can’t be “accidental mix”. And here the ambiguity is possible, while selecting Cowper–Symonds (C and P) constants. Both of them belong to Cowper–Symonds yield limit scaling model and to some extent are able to compensate each other. The main difficulties in FEM modeling are the description of the material behavior law. The choice of Cowper–Symonds law simplifies the material experimental testing; on the other hand strain rate parameters need empirical selection. As it is demonstrated earlier on the paper Smooth Particle hydrodynamics (SPH) methodology, using Cowper–Symonds law need less material characteristics for high impact material deformation with material failure. And the material failure is based on neighbor particles search. Second raison to use SPH methodology was, that FEM was very time consuming method. The orthogonal turning study showed the FE modeling problems. All complicity and ambiguities found in orthogonal turning modeling of drilling modeling could only progress just for one reason – the complicated geometry of drilling tool. In FE modeling this circumstance could complicate the contact search. Finally, the 3D drilling simulation was performed using SPH methodology. Calculated axial force was less than 5% according to experiments. But finally, as it was presented no material properties identification was needed.

[Komanduri 2001] Komanduri R. and Hou, Z. B. A Review of the Experimen-tal Techniques for the Measurement of Heat and Temperatures Generated in some Manufacturing Processes and Tribology. Tribol. Int., October 2001, Vol. 34, No. 10, p. 653–682. [Kountanya 2004] Kountanya R. K. and Endres, W. J. Flank Wear of Edge-Radi-used Cutting Tools under Ideal Straight-Edged Orthogonal Conditions. J. Ma-nuf. Sci. Eng. -Trans. Asme, August 2004, Vol. 126, No. 3, p. 496–505. [Villumsen 2008] Villumsen M. F. and T. G. Fauerholdt T. G. Simulation of Me-tal Cutting Using Smooth Particle Hydrodynamics. Tagungsberichtsband Zum -DYNA Anwenderforum Bamb., 2008, Vol. 30, No. 01. [Limido 2007] Limido, J. et al. SPH Method Applied to High Speed Cutting Mo-deling. Int. J. Mech. Sci., September 2007, Vol. 49, No. 7, p. 898–908. [Barauskas 2007] Barauskas, R. and Abraitiene, A. Computational Analysis of Impact of a Bullet Against the Multilayer Fabrics in LS-DYNA. Int. J. Impact Eng., July 2007, Vol. 34, No. 7, p. 1286–1305. [Hallquist 2006] Hallquist, J. LS-DYNA Theory manual. Livermore software technology corporation, 2006, ISBN 0-977-8540-0-0. [Dey 2006] Dey, S., Borvik, T., Hopperstad, O. S, Langseth, M. On the Influence of Fracture Criterion in Projectile Impact of Steel Plates. Computational Mate-rials Science, 2006, Vol. 38, p. 176–191. [Raczy 2004] Raczy, A., Altenhof, W. J. and Alpas, A. T. An EulerianFinite Ele-ment Model of the Metal Cutting Process. Proceedings of the 8th International LS-Dyna Users Conference, 2004, p. 11-26.


HSM2014–14078

INVESTIGATION OF HEXAPOD ROBOT DYNAMICS AND ITS EFFECTS IN MILLING

L. T. Tunc1*, J. Barnfather2

1NUCLEAR AMRC, UNIVERSITY OF SHEFFIELD, SHEFFIELD, UNITED KINGDOM2THE DEPARTMENT OF MECHANICAL, AEROSPACE AND CIVIL ENGINEERING, MANCHESTER UNIVERSITY


ABSTRACTRobotic machining, promoting the mobile manufacturing, is considered to be a much more cost effective and portable alternative to CNC machining. Thus, it is started to be used in manufacturing of large scale components designed in industries such as aerospace and nuclear. Robotic machining involves trade-offs contrast to the opportunities it offers. Robots used in mobile machining is known with their low dynamic rigidity, mode coupling and position dependent dynamics contrary to CNC machine tools. In this paper, dynamics and stability of robotic machining is identified with focus

[Abele 2007] Abele, E., Weigold, M., RothenBücher, S., Modeling and Identifi-cation of an Industrial Robot for Machining Applications, Annals of the CIRP, 2007, Vol. 56, 387-390. [Abele 2010] Abele, E., Baer, J., Pischan M., Stryk O. v., Friedmann, M., and Hemker, T., Prediction of the tool displacement for robotic milling applications using coupled models of an industrial robot and removal simulation. In: Proce-edings of the CIRP 2nd International Conference on Process Machine Interac-tions, Vancouver, BC, Canada, June 10–12, 2010. [Barnfather 2013] Barnfather, J. and Abram, T. Positional Capability of the Fa-nuc F-200iB Hexapod for Machining Applications in the Nuclear Industry. [Budak 1998] Budak, E., and Altintas, Y., Analytical Prediction of Chatter Stabi-lity in Milling—Part I: General Formulation, ASME Journal of dynamic systems, measurement, and control, 1998, Vol. 120, 22-30. [Dumas 2011] Dumas, C., Caro, S., Garnier, S., and Furet, B., Joint Stiffness identification of six-revolute industrial serial robots, Robotics and Computer--Integrated Manufacturing, 2011, 27: 881-888. [Fassi 2000] Fassi, I., and Wiens, G. J. Multiaxis Machining: PKMs and Traditional Machining Centers, Journal Manufacturing Processes, 2000, Vol. 2, No: 1, 1–14. [ISO 1998] BS EN ISO 9283 Manipulating Industrial Robots – Performance Cri-teria and Related Test Methods. [Leica 2010] Leica. Absolute Tracker AT401 ASME B89. 4. 19-2006 Specifica-tion. URL http://www.leica-geosystems.com/downloads123/m1/metrology/AT401/brochures-datasheet/Leica Absolute TrackerAT401-ASMEspecificati-ons\_en.pdf.[Lobato 2011] Lobaho, H. The challenges for dimensional inspection in the ma-nufacture of large pressure vessels for the Nuclear Industry, Large Volume Metrology Conference, 15–16 November 2011.

Mobile machining; chatter; dynamics; stability; hexapodKEYWORDS

REFERENCES

on the analysis of the system’s dynamic and positional behavior during milling, where FANUC F200ib hexapod robotic machining platform is used. After identifying the sources of flexibilities, process stability models are applied in order to establish chatter free cutting conditions for improved productivity. Besides, the positional capability of the hexapod robot is also discussed in details to establish relation between the dynamic flexibility and static flexibility. The results are verified through experimental cases and conclusions are derived with future work to be done.

[Ozturk 2010] Ozturk, E., Budak, E., Dynamics and stability of five axis ball end milling, Journal of Manufacturing Science and Engineering, Transactions of the ASME, 2010, 132. [Pan 2006] Pan, Z., Zhang, H., Zhu, Z., and Wang, J. Chatter Analysis of Ro-botic Machining Process, Journal of Materials Processing Technology, 2006, 173, 301-309. [Pandremenos 2011] Pandremenos, J., Doukas, C., Stavropoulos, P., Chrysso-louris, G., 7th International Conference on Digital Enterprise Technology, Athens, 28-30 September 2011. [Patel 1997] Patel, A. J., and Ehmann, K. F., Volumetric Error Analysis of a Ste-wart Platform-Based Machine Tool, Annals of the CIRP, 1997, Vol. 46–1, 287-290. [Shneor 2010] Shneor, Y., and Portman, V. T. Stiffness of 5-axis machines with serial, parallel and hybrid kinematics: Evaluation and comparison, Annals of CIRP, 2010, Vol. 59, 409-412. [Slavkovic 2013] Slavkovic, N. R., Milutinovic, D. S., Glavonjic, M. M., A method for off-line compensation of cutting force-induced errors in robotic machining by too path modification, 2013, Int J Adv Manuf Techol. [Song 2000] Song, J., and Mou, J. I., King, C. Parallel Kinematic Machine Posi-tioning Accuracy Assesment and Improvement, Journal Manufacturing Proce-sses, 2000, Vol. 2, No: 1, 48-58. [Tlusty 1999] Tlusty, J., Ziegert, J., Ridgeway, S. Fundamental Comparison of the Use of Serial and Parallel Kinematics for Machine Tools, Annals of the CIRP, 1999, Vol. 48, 351-356. [Zaghbani 2013] Zaghbani, I., Songmene, V., and Bonev, I. An experimental stu-dy on the vibration response of a robotic machining system, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manu-facture, 2013, 227(6), 866-880.


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HSM2014–14044

CHATTER SUPPRESSION IN A HIGH SPEED MAGNETIC SPINDLE BY ADDING DAMPING

L. Uriarte1*, I. Etxaniz1, I. Iturbe1, M. Zatarain2, J. Munoa2

1IK4-TEKNIKER, MECHATRONICS DEPT., EIBAR, BASQUE COUNTRY, SPAIN2IK4-IDEKO, DYNAMICS & CONTROL DEPT., ELGOIBAR, BASQUE COUNTRY, SPAIN


ABSTRACTMagnetic bearings are used in several applications, but they didn’t succeed in the machine tool industry, due basically to their low damping, with its associated low chatter free cutting capacity. This work shows the development of a high speed milling spindle supported on magnetic bearings with high chatter resistance.

[Gebert 2007] Gebert, K. (WEISS GmbH). 2007. Motor spindles – Latest sta-te of technology, STC M, 57th CIRP General Assembly, Dresde (Germany). [SKF 2014] www.skfmagneticbearings.com[Smith 2006] Smith, S. (discussion). 2006. Minutes of the 8th Meeting of the CIRP Working Group “PMI”, Kobe (Japan). [Coombs 1999] Coombs, T., Campbell, A. M., Storey, R., Weller, R. 1999. Superconducting magnetic bearings for energy storage flywheels. IEEE Trans. on Applied Superconductivity, 9/2: 968-971. [Lacour 2005] Lacour, M. (S2M company). 2005. Magnetic bearings and machine tools applications, STC M, CIRP January meetings, Paris (France). [Weck 1999] Weck, M., Hennes, N., Krell, M. 1999. Spindle and Toolsystems with High Damping. Annals of the CIRP, 48/1: 297–302.

Magnetic bearings; spindle; dampingKEYWORDS

REFERENCES

That is achieved by using control strategies which add damping to the bearings. Excitation by means of the magnetic bearings is used to identify its dynamic behaviour and to optimize the damping parameters. Finally the results of the industrial validation are presented; showing an increase of six times in the cutting capacity.

[Neugebauer 2007] Neugebauer, R., Denkena, B., Wegener, K. 2007. Me-chatronic Systems for Machine Tools. Annals of the CIRP, 56/2: (keynote). [Abele 2006] Abele, E., Kreis, M., Roth, M. 2006. Electromagnetic Actuator for in Process Non-Contact Identification of Spindle-Tool Frequency Re-sponse Functions. CIRP 2nd Int. Conf. on HPC, Vancouver (Canada). [Etxaniz 2006] Etxaniz, I., Izpizua, A., Arana, J., San Martin, M. 2006. De-sign and manufacture of a spindle with magnetic bearings for high speed machining. CIRP 5th Int. Conf. on High Speed Machining, Metz (France), 1: 355–360. [Munoa 2009] Munoa, J., Zatarain, M., Dombovari, Z., Yang, Y., 2009. Effect of mode interaction on stability of milling processes. 12th CIRP Conferen-ce on Modelling of Machining Operations, San Sebastian (Spain), 927-933.

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HSM2014–14050

A METHOD OF IDENTIFICATION OF COMPLEX CUTTING FORCES ACTING IN UNSTABLE CUTTING PROCESS

P. Bach1*, M. Poláček1, P. Chvojka1, D. Burian1, J. Drobílek1

1CZECH TECHNICAL UNIVERSITY IN PRAGUE, FACULTY OF MECHANICAL ENGINEERING, RCMT, PRAGUE, CZECH REPUBLIC


ABSTRACTThe calculations of machining stability limit currently known do not provide a precise prediction of chatter-free cutting conditions. The inaccuracy is probably caused by mathematical models of dynamic forces acting on the cutting process during unstable machining. These models need to be modified. A new analysis of experimental data measured by one of the authors, M. Poláček, in the 1968–1974 period, forecasted an existence of several

[Altintas 2008] Altintas, Y., et al. Identification of dynamic force coefficients and chatter stability with process damping. CIRP Annals – Manufacturing Technolo-gy, 2008, 57, p. 371-374. [Bach 2013a] Bach, P., et al., Comparative Analysis of Lower Speed Chatter Behaviour, MM Science Journal, 2013, no. 12. ISSN 1212-2572. Accessible from: <http://www.mmscience. eu/201314>. [Bach 2014b] Bach, P., et al. Dynamic Forces in Unstable Cutting During Tur-ning Operations, Manufacturing Technology, Vol. 14, No. 1, 2014, p. 3 – 8. ISSN 1213-2489. [Daněk 1963] Daněk, O., et al. SelbsterregteSchwingungenanWerkzeugmaschi-nen, VerlagTechnik Berlin. 1963. [Eynian 2010] Eynian, M. Chatter Stability of Turning and Milling with Process Damping, Vancouver: A Thesis for the Degree of Ph. D., University of British Co-lumbia, 2010. [Goel 1976] Goel, B. S. Measurement of Dynamic Cutting Force Coefficients. A Thesis for the Degree of Ph. D. Hamilton: McMaster University. 1976. [Jemielniak 1992] Jemielniak, K. Modeling of Dynamic Cutting Coefficients in Three-Dimensional Cutting, Int. J. Mach. Tools Manufacturing, August 1992, 32, 4, 509-519. Tool Design and Research, 1972, 12, 3, 201–220. [Liu 1985] Liu, C. R., Liu, T. M. Automated Chatter Suppression by Tool Geometry Control, Journal of Engineering for Industry, 1985, 107, 2, 95–100. [Peters 1972] Peters, J., et al. The Measurement of the Dynamic Cutting Coeffi-cient. CIRP Annals, 1972, 2, 21.

Chatter; stability inaccuracy; complex cutting forces; forces identificationKEYWORDS

REFERENCES

dynamic forces, which are mutually phase-shifted, thus complex. This fact has not been thoroughly investigated previously. As the assumed forces cannot be calculated from any equations, they must be identified experimentally. This research paper proposes a theoretical method of an experimental identification of these forces. The new model is intended to be used in the future for the development of a more accurate calculation of stability diagram.

[Poláček 1955] Poláček, M. Stability calculation of a machine tool structure, Ph. D. thesis, CUT in Prague. 1955 (in Czech). [Poláček 1968] Poláček, M. Device for Measurement of the Dynamic Cutting Force Coefficient (in Czech), Research report of VÚOSO in Prague, 1968. [Poláček 1969] Poláček, M. Dynamic Cutting Force Coefficients for the steel AISI1045 (C45) CSN12050, [Poláček 1969] Poláček, M. Method of Measurement of the Dynamic Cutting For-ce Coefficient, (in Czech), Research report of VÚOSO in Prague, 1969. [Poláček 1970] Poláček, M. Dynamic Cutting Force Coefficient, (in Czech), Research report of VÚOSO in Prague, 1970. [Poláček 1971] Poláček, M. Dynamic Cutting Force Coefficient, (in Czech), Research report of VÚOSO in Prague, 1971. [Poláček 1974] Poláček, M. Influance of the Dynamic Cutting Force Coefficient on Stability Limit Calculation, (in Czech), Research report of VÚOSO in Prague, 1974. [Rao 1977] Rao, S. B. Analysis of Dynamic Cutting Force Coefficient. A Thesis for the Degree of Ph. D. Hamilton: McMaster University. 1977. [Tlusty 1978] Tlusty, J. Analysis of the Research in Cutting Dynamics. Annals of the CIRP, 1978, 2, 27, p. 583-589. [Tlusty 1976] Tlusty, J., et al. The Dynamic Cutting Coefficient for Some Carbon Steels, Proc. 4th NAMR Conf., Battelle’s Labs, Columbus. 1976. [Tunc 2012] Tunc, LT., Budak E. Effect of cutting conditions and tool geometry on process damping in machining. Int. Journal of Machine Tools & Manufacture, 2012, Vol. 57, p. 10–19.


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HSM2014–14029

HIGH SPEED MACHINING OF PROFILED GROOVES IN NICKEL-BASED ALLOYS

F. Klocke1, D. Lung1, P. Vogtel1, M. Binder1*

1WZL, LABORATORY FOR MACHINE TOOLS AND PRODUCTION ENGINEERING, RWTH AACHEN UNIVERSITY, GERMANY


ABSTRACTThe connection between rotor disc and blade in turbine applications is usually realized by complex profiled grooves. The profiled grooves are mostly manufactured by broaching processes. In compressor and fan applications, alternative cutting processes such as milling and broaching with more advanced cutting materials are already implemented. In turbine applications, where nickel-based alloys are used due to high forces and temperatures, the use of HSS-tools is still state of the art. Due to the low high temperature

[Airbus 2013] Airbus, N. N. Global Market Forecast 2013-2032. Published by Airbus S. A. S., 2013[Bayer 2011] Bayer, E. Fertigungsprozesse als Schlüsseltechnologie zur Re-alisierung des Geared Turbo Fan. In: Technikbericht der MTU Aero Engines. [Curtis 2009] Curtis, D. T. et al. Electrochemical superabrasive machining of a nickel-based aeroengine alloy using mounted grinding points. CIRP Annals – Manufacturing Technology 58 (2009), p. 173–176[Curtis 2008] Curtis D. T. et al. Production of complex blade mounting slots in turbine discs using novel machining techniques. Proceedings of the 3rd CIRP International Conference on High Performance Cutting, HPC 2008[Gerloff 2014] Gerloff S. Herausforderungen an die spanende Bearbeitung. MTU Aero Engines GmbH. http://www.mtu.de/de/technologies/engineering_news/others/Gerloff_Herausforderungen_spanende_Bearbeitung_de.pdf[Gerschwiler 2002] Gerschwiler, K. Drehen und Fräsena von Nickelbasisle-gierungen. In: Perspektiven der Zerspantechnik – Entwicklung und Integra-tion der Fertigungsprozess von morgen. 2002[Klocke 2013a] Klocke, F. et al. Broaching of Inconel 718 with cemented car-bide. Prod. Eng. Res. Devel. 11/2013 (2013) DOI 10. 1007/s11740-013-0483–1[Klocke 2013b] Klocke. F. et al. Impact of Cutting Speed and Material on Sur-

High speed machining; broaching; milling; nickel-based alloysKEYWORDS

REFERENCES

strength of this cutting material, cutting speeds do not exceed 2-5 m/min. The use of alternative manufacturing processes for roughing therefore has a high potential. This paper presents and discusses alternative high speed machining processes such as milling with ceramic cutting tools at elevated cutting speeds (up to 800 m/min) and broaching with tungsten carbide which offers the advantages of broaching at multiple cutting speeds (up to 20 m/min) compared to broaching with HSS-tools.

face Quality in Broaching of Nickel-Based Alloys. Proceedings of the 9th In-ternational Conference on High Speed Machining HSM. 2013[Klocke 2012] Klocke, F. et al. Developments in Wire-EDM for the manufactu-ring of fir-tree slots in turbine discs made of Inconel 718. Key Engineering Materials (2012), p. 504-506[Klocke 2008] Klocke, F.; König, W. Fertigungsverfahren. Drehen, Fräsen, Bohren. [Makarov 2008] Makarov, V. F. et al. High speed broaching of hard machining materials. Int. J. Mater. Form (2008), p. 547-550[Mo 2005] Mo, S. P. et al. An example of selection of the cutting conditions in broaching of heat-resistant alloys based on cutting forces, surface roughness and tool wear. Journal of Materials Processing Technology 160 (2005), p. 382-389[Pöhls 2000] Pöhls, M. Untersuchungen zum Räumen mit Feinstkornhart-metall und Cermet. Dissertation RWTH Aachen, 2000[Reed 2006] Reed, R. C. The Superalloys – Fundamentals and Applications. 2006, Cambridge University Press, Cambridge[Vogtel 2014] Vogtel, P. et al. High Performance Machining of Profiled Slots in Nickel-Based-Superalloys. Proceedings of the 6th CIRP International Con-ference on High Performance Cutting, HPC 2014[Wiemann 2006] Wiemann, E. Hochleistungsfräsen von Superlegierungen. Dissertation TU Berlin, 2006


HSM2014–14076

ANALYSIS AND MEASUREMENT OF CUTTING TEMPERATURE IN HIGH SPEED MACHINING OF ALUMINUM ALLOY

T. Obikawa1*, A. Basti2, J. Shinozuka3

1INSTITUTE OF INDUSTRIAL SCIENCE, THE UNIVERSITY OF TOKYO, TOKYO, JAPAN2DEPARTMENT OF MECHANICAL ENGINEERING, UNIVERSITY OF GUILAN, RASHT, IRAN3DEPARTMENT OF MECHANICAL ENGINEERING, YOKOHAMA NATIONAL UNIVERSITY, YOKOHAMA, JAPAN


ABSTRACTIn automobile and aerospace industries, high speed machining of aluminum alloy is increasingly required. However, the strong adhesion of aluminum alloy to a cutting tool is a big problem. Thus, the analysis and measurement of cutting temperature on the tool face were conducted in this study for investigating the thermo-mechanical conditions of the tool-work contact area at high cutting speeds. The finite volume method was used for the temperature analysis in the orthogonal machining. The thermal conductivities of tool and work materials and the specific heat of

[Basti 2007] Basti, A., Obikawa, T. and Shinozuka J. Tools with built-in thin film thermocouple sensors for monitoring cutting temperature. Internatio-nal Journal of Machine Tools and Manufacture, 2007, Vol. 47, pp. 793-798. [Dosbaeva 2008] Dosbaeva, J., Fox-Rabinovich, G., Dasch, J. and Veldhuis, S. Enhancement of wet- and MQL-based machining of automotive alloys using cutting tools with DLC/polymer surface treatments, Journal of Mate-rials Engineering and Performance, 2008, Vol. 17. pp. 346–351. [Fox-Rabinovich 2011] Fox-Rabinovich, G., Dasch, J. M., Wagg, T., Yamamo-to, K., Veldhuis, S., Dosbaeva, G. K. and Tauhiduzzaman, M. Cutting perfor-mance of different coatings during minimum quantity lubrication drilling of aluminum silicon B319 cast alloy. Surface & Coatings Technology, 2011, Vol. 205, pp. 4107–4116. [Hanyu 2003] Hanyu, H., Kamiya, S., Murakami, Y. and Saka, M. (2003) Dry and semi-dry machining using finely crystallized diamond coating cutting tools, Surface and Coatings Technology, 173 –174. pp. 992–995. [Inasaki 2001] Inasaki, I., Karpuschewski, B. and Tonshoff, H. K. Cutting Processes. In: H. K. Tonshoff and I. Inasaki Ed. Sensors Monitoring in Ma-nufacturing. Weinheim: Wiley-VCH, 2001. [Kamio 2007] Kamio, K., Obikawa, T. Basti, A., Shinoduka, J. and Kamata, Y. Development of a DLC-coated Tool with thin film thermocouples. In: Oni-kura ed. Proceedings of the 4th International conference on Leading Edge manufacturing in 21st Century, 2007, Fukuoka: JSME, pp. 323-326. [Kishawy 2005] Kishawy, H. A., Dumitrescu, M, Ng, E. G. and Elbestawi, M. A. Effect of coolant strategy on tool performance, chip morphology and surface quality during high-speed machining of A356 aluminum alloy.

Cutting temperature; high speed machining; aluminum alloy; finite volume method; thin film thermocoupleKEYWORDS

REFERENCES

the work were temperature dependent. As for the measurement of cutting temperature in orthogonal high speed machining, thin film thermocouples of Ni and Ni-Cr, which were fabricated on the tool face by photolithography, were used. The stress on the rake face is obtained from the cutting forces based on a modeling of stress distribution proposed by one of authors. The temperature distributions on the rake face obtained through the analysis for different cutting speeds were consistent with those measured with the thin film thermocouples.

International Journal of Machine Tools and Manufacture, 2005, Vol. 45, pp. 219-227. [Klocke 1997] Klocke, F. and Rehse, M. Intelligent tools through integrated micro systems. Production Engineering, 1997, Vol. 4, pp. 65-68. [Obikawa 1997] Obikawa, T., Matsumura, T., Shirakashi, T. and Usui, E. Wear characteristic of alumina coated and alumina ceramic tools. Journal of Materials Processing Technology, 1997, Vol. 63, pp. 211-216. [Obikawa 1998] Obikawa T. Cutting. In: H. Nakazawa ed. Principles of Manu-facturing. Tokyo : Nikkan Kogyo Shimbun, 1998, pp. 103–123 (in Japanese). [Patankar 1980] Patankar, S. V. Numerical Heat Transfer and Fluid Flow. Washington D. C.: Hemisphere, 1980. [Shinozuka 2008] Shinozuka, J., Basti, A. and Obikawa, T. Development of cutting tool with built-in thin film thermocouples for measuring high temperature fields in metal cutting processes. Journal of Manufacturing Science and Engineering, Transactions of the ASME, 2008, Vol. 130, pp. 034501–1-6. [Touloukian 1970a] Touloukian, Y. S., Powell, R. W., Ho C. Y. and Klemens, P. G. Thermal Conductivity, Metallic Elements and Alloys. NewYork: IFI/Plenum, 1970. [Touloukian 1970b] Touloukian, Y. S., Powell, R. W., Ho C. Y. and Klemens, P. G. Thermal Conductivity, NonmetallicSolids. NewYork: IFI/Plenum, 1970. [Touloukian 1970c] Touloukian, Y. S. and BuycoE. H. Specific Heat, Metallic Elements and Alloys. NewYork: IFI/Plenum, 1970. [Usui 1984] Usui, E., Shirakashi, T. and Kitagawa, T. Analytical prediction of cutting-tool wear. Wear, 1984, vol. 100, pp. 129–151.


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HSM2014–14071

HIGH SPEED GEAR HOBBING WITH CEMENTED CARBIDE HOBS

B. Karpuschewski1, M. Beutner1, M. Wengler1*, M. Köchig1

1OTTO VON GUERICKE UNIVERSITY MAGDEBURG, INSTITUTE OF MANUFACTURING TECHNOLOGY AND QUALITY MANAGEMENT (IFQ), UNIVERSITÄTSPLATZ 2, 39106 MAGDEBURG, GERMANY


ABSTRACTAs dominating manufacturing process to produce external gears, hobbing is of major importance for the gearing industry. Containing up to 80% of the gear production the automobile sector always demands improved processes. On the one hand to shorten the production time and one the other hand to open up a bottleneck in the production. Changing the cutting material could be a basic solution. It is widely known that cemented carbide endures higher cutting speeds compared to HSS / PM- HSS. Due to the higher acquisition costs and the lack of knowledge most of the companies hesitate to use cemented carbide hobs. Hence, the aim of the research project is to generate experience- based knowledge, which

[Falk 2013] Falk, T., Kretzschmann, U. Toothing milling more rapid, in: Werkstatt und Betrieb, 06/2013, p. 61-63[Hipke 2011] Hipke, M. Wälzfräsen mit pulvermetallurgischhergestelltem Schnellarbeitsstahl, Dissertation OvGU, IFQ Magdeburg, 2011[Hoffmeister 1970] Hoffmeister, B. Über den Verschleiß am Wälzfräser, Dissertation, RWTH Aachen, 1970[Joppa 1977] Joppa, K. Leistungssteigerung beim Wälzfräsenmit Schnellar-beitsstahl durch Analyse, Beurteilung und Beeinflussung des Zerspanproze-sses, Dissertation RWTH Aachen, 1977[Kleinjans 2003] Kleinjans, M. Einfluss der Rand-zoneneigenschaften auf den Verschleiß von beschichteten Hartmetallwerkzeugen, Dissertation RWTH Aachen, 2003[Klocke 2000] Klocke, F. Kühlschmierstofffreie Fertigung von Stirnrädern – Spanbildungskenngrößen, Abschlussbericht Forschungs-vorhaben AiF 11256 N, 2000[Klocke 2010] Klocke, F., et. al. Comparison of PM-HSS and Cemented Car-bide Tools in High-Speed Gear Hobbing, in: Gear Technology, 10/2009, p. 57-59[Knöppel 1996] Knöppel, D. Trockenbearbeitung beim Hochgeschwindigkeits-

Gear hobbing; cemented carbide; wear behavior; fly cuttingKEYWORDS

REFERENCES

can be offered to the end- user. Within the project established cemented carbide substrates is used to investigate three different industrial gearings. To realize the experimental tests the fly cutter test was used. Furthermore, cutting and process parameters where changed in order to investigate their influence on the wear behaviour. Comparing to the industrial cutting parameters the applied ones can be called “high speed”. At the end of tool life the fly cutting teeth where documented using structured light scanning and electron microscope, to examine the wear behaviour precisely. Summarizing the wear behaviour was categorized and matched with geometrical interpenetration simulation (e. g. chip thickness and cutting length).

-wälzfräsen mit beschichteten Hartmetall-Werkzeugen, Dissertation RWTH Aachen, 1996[Kobialka 2001] Kobialka, C. Prozessanalyse für das Trockenwälzfräsen mit Hartmetall-werkzeugen, Dissertation RWTH Aachen, 2001[McGuinn 2013] Mc Guinn, J. The Global Gear Industry, in: Gear technology 5/2011, P. 33 – 38[N. N. 2014a] N. N. Toothing milling more rapid, in: SMM Schweizer Maschine-nmarkt, Vol. 115, Iss. 7 , 2014, p. 64-69[N. N. 2014b] N. N. Organisation Internationale des Constructeurs d’Automo-biles, http://www.oica.net/category/production-statistics, visited 10. May 2014[Stuckenberg 2011] Stuckenberg, A., Gorgels, A., Klocke, F. Investigations on surface defects, in: gear hobbing, Procedia Engineering, Volume 19, 2011, p. 196-202[Wennmo 2014] Wennmo, M., Holopainen, M. The Technology Shift HSS vs. Indexable in Gear Hobbing, Gear Technology, 05/2014, p. 36-39[Winkel 2004] Winkel, O. Steigerung der Leistungsfähigkeit von Hartmetall--wälzfräserndurcheineoptimierte Werkzeuggestaltung, Dissertation RWTH Aachen, 2004


HSM2014–14012

ANALYTICAL TIME-DOMAIN MODEL FOR TOOL POINT DYNAMICS IN TURNING

L. Berglind1*, J. Ziegert1

1UNCC, FACULTY OF MECHANICAL ENGINEERING, CHARLOTTE, NC, USA


ABSTRACTThe dynamic response of a tool during a turning operation is dependent on regenerative effects, where tool point vibrations from a previous pass influence the tool point vibrations during the current pass. Over time these regenerative effects cause the tool to be stable or unstable (chatter) depending on the parameters of the system and the cutting process. Dynamic stability is often determined in the frequency domain by predicting whether vibration amplitudes increase or decrease in successive passes. Stability can also be determined by observing the time-domain response of the tool; however, the time-domain is not as well suited for stability analysis

[Altintas 1995] Altintas, Y., Budak, E. Analytical Prediction of Stability Lobes in Milling. Annals of CIRP, 1995, Vol. 44, No. 1. [Bayly 2003] Bayly, P. V., Halley, J. E., Mann, B. P., Davies, M. A. Stabi-lity of Interupted Cutting by Temporal Finite Element Analysis. Journal of Manufacturing Science and Engineering, 2003, Vol. 125, No. 2, pp. 220-225. [Davies 2002] Davies, M. A., Pratt, J. R., Dutterer, B., Burns, T. J. Stability Prediction for Low Radial Immersion Milling. Journal of Manufacturing Science and Engineering, 2002, Vol. 124, pp. 217-225. [Insperger 2002] Insperger, T., Stepan, G. Semi-Discretization Method for Delayed Systems. International Journal for Numerical Methods in Engineering, 2002, Vol. 55, No. 5, pp. 503-518. [Insperger 2004] Insperger, T., Stepan, G. Updated Semi-Deiscretization Method for Periodic Delay Differential Equations. International Journal for Numerical Methods in Enginee-ring, 2004, Vol. 61, pp. 117–141. [Merdol 2004] Merdol, S. D., Altintas, Y. Multi Frequency Solution of Chatter Stability for Low Immersion Milling. Journal of Manufacturing

Machine dynamics; chatter; turning; analytical time-domain model: superpositionKEYWORDS

REFERENCES

because… it is difficult to describe tool point dynamics analytically due to the delay differential equation (DDE) describing the system dynamics. In this paper an alternative approach is used to solve for the time response of the tool analytically without the need to solve the DDE directly. This approach uses the superposition principal under the linear assumption to construct a global time domain response for a single degree of freedom, single mode turning operation. The accuracy of the analytical solution is determined by comparing the time responses to those obtained using numerical integration techniques.

Science and Engineering, 2004, Vol. 126, pp. 459-466. [Myshkis 1998] Myshkis, A. D. Differential Equations, Ordinary with Distribu-ted Arguments. Encyclopedia of Mathematics. Boston, Kluwer Academinc Publishers, 1998, Vol. 3, pp144–147. [Ozoegwu 2012] Ozoegwu, C. G., Omenyi, S. N. Time Domain Chatter Stability Comparison of Turning and Milling Processes. International Journal of Multidisciplinary Sciences and Engineering, 2012, Vol. 3, No. 11, pp. 25. [Schmitz 2009] Schmitz, T. L., Smith, K. S. Machining Dynamics – Fre-quency Response to Improved Productivity. New York, NY, Springer, 2009. [Shampine 2001] Shampine, L. F., Thompson, S. Solving DDEs in Matlab. Applied Numerical Mathematics, 2001, Vol. 37, pp. 441-458. [Tlusty 1981] Tlusty, J., Ismail, F. Basic Non-linearities in Maching Chatter. "Annals of CIRP, 1981, Vol. 30, pp. 299-304. [Tlusty 1963] Tlusty, J., Polacek, W. The Stability of Machine Tools Against Self Excited Vibrations. ASME International Research in Pro-ductoin Engineering, 1963, Vol. 1, pp. 465-474.


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HSM2014–14034

OPTIMAL CONTROL LAWS FOR CHATTER SUPPRESSION USING INERTIAL ACTUATOR IN MILLING PROCESSES

I. Mancisidor1*, J. Munoa1, R. Barcena2

1DYNAMICS AND CONTROL, IK4-IDEKO, ELGOIBAR, BASQUE COUNTRY, SPAIN2DEPARTMENT OF ELECTRONIC TECHNOLOGY, UNIVERSITY OF THE BASQUE COUNTRY (UPV/EHU), BILBAO, BASQUE COUNTRY, SPAIN


ABSTRACTActually, active control devices are considered as one of the most suitable chatter suppression methods for heavy duty machining operations. Generally, they are based on the generation of a reaction force over the main structure, controlled by a feedback control law, which depends on the real time vibration measurement. Several active control strategies have been proposed in the literature and due to the limited space offered by the machines for these actuators, the active control system has to be optimized, including the control law. In this work, the most employed

[Altintas 2012] Altintas, Y. Manufacturing Automation. Cambridge Universi-ty Press, 2nd Edition, 2012. [Baur 2012] Baur, M., Zaeh, M. F. Development and Experimental Validati-on of an Active Vibration Control System for a Portal Milling Machine. Pro-ceedings of 9th International Conference on High Speed Machining, San Sebastian, Spain, March 7-8, 2012. [Bediaga 2009] Bediaga, I., Zatarain, M., Munoa, M., Zelaieta, O. Analysis of Stability of Structural Modes in Milling Processes. 5th CIRP International Conference and Exhibition on Design and Production of Machines and Dies/Molds, Kusadasi, Turkey, 2009. [Brecher 2005] Brecher, C., Schulz, A. and Week, M. Electrohydraulic Active Dam-ping System. CIRP Annals – Manufacturing Technology, Vol. 54, No. 1, pp. 389-392. [Brecher 2012] Brecher, C. and Brockmann, B. Membrane based high dy-namic hydraulic actuator for active damping system in machine tools. Pro-ceedings of 9th International Conference on High Speed Machining, San Sebastian, Spain, March 7-8, 2012. [Bilbao-Guillerna 2010] Bilbao-Guillerna, A., Barrios, A., Mancisidor, I., Loix, N. and Munoa, J. Control laws for chatter suppression in milling using an inertial actuator. Proceedings of ISMA 2010, Leuven, Belgium, Septem-ber 20-22, 2010. [Brecher 2004] Brecher, C. and Schulz, A. Active Auxiliary Mass Damper. Proceedings of ISMA 2004, Leuven, Belgium, September 20-22, 2004. [Cowley 1970] Cowley, A. and Boyle, A. Active Dampers for Machine Tools. CIRP Annals – Manufacturing Technology, Vol. 18, No. 1, pp. 213-222. [Den Hartog 1956] Den Hartog, J. P. Mechanical Vibrations. McGraw-Hill, 4th Edition, New York, 1956. [Ehmann 2002] Ehmann, C. and Nordmann, R. Low Cost Actuator for Active Damping of Large Machines. IFAC Conference on Mechatronic Systems, Berkeley, USA, 2002. [Ewins 2000] Ewins, D. J. Modal Testing: Theory, Practice and Application. Research Studies Press Ltd., Baldock, Hertfordshire, England, 2000. [Fuller 1996] Fuller, C. R., Elliot, S. J. and Nelson, P. A. Active Control of Vi-bration. Academic Press Limited, 1996. [Huyanan 2007] Huyanan, S. and Sims, N. D. Vibration Control Strategies for Proof-mass Actuators. Journal of Vibration and Control, 2007, Vol. 13, No. 12, pp. 1785–1806.

Chatter; active control; inertial actuatorKEYWORDS

REFERENCES

strategies will be compared by means of a verified mechatronic model and the optimal law will be sought for each zone of stability lobes. Moreover, complex stability lobes will be studied, where chatter vibrations due to flip bifurcations and mode coupling effect are considered. In this way, different cutting conditions will be studied, where continuous and interrupted cutting conditions are simulated. Finally, experimental tests will be performed for verifying the results obtained by the mechatronic model simulations.

[Loix 2004] Loix, N. and Verschueren, J. P. Stand-alone active damping de-vice. Actuator 2004 – 9th International Conference on New Actuators, Bre-men, Germany, June 14–16. [Mancisidor 2013] Mancisidor, I., De la Fuente, J., Barrios, A., Barcena, R. and Munoa, J. Diseño de un amortiguador activo para la eliminación de chatter en máquina herramienta. 19 Congreso de Máquinas-Herramien-ta y Tecnologías de Fabricación, San Sebastián, Spain, June 12–14, 2013. [Munoa 2005] Munoa, J., Zatarain, M., Bediaga, I. and Lizarralde, R. Optimi-zation of Hard Material Roughing by means of a Stability Model. 8th CIRP International Workshop on Modelling of Machining Operations, Chemnitz, Germany, May 10–11, 2005. [Munoa 2009] Munoa, J., Zatarain, M., Dombovari, Z. and Yang, Y. Effect of mode interaction on stability of milling processes. Proceedings of the 12th CIRP Conference on Modelling of Machining Operations, San Sebastian, Spain, May 7-8, 2009. [Munoa 2013] Munoa, J., Mancisidor, I., Loix, N., Uriarte, L. G., Barcena, R. and Zatarain, M. Chatter suppression in ram type travelling column milling machine using biaxial inertial actuator. CIRP Annals – Manufacturing Tech-nology, 2013, Vol. 62, No. 1, pp. 407-410. [Ogata 1970] Ogata, K. Modern Control Engineering, Prentice-Hall Inc., 1970. [Preumont 2002] Preumont, A. Vibration Control of Active Structures: An Introduction. Kluwer Academic Publishers, 2002. [Sabalza 2004] Sabalza, X., Munoa, J., Mugica, I., Uribe-Etxeberria, R. and Lizarralde, R. Incremento de la capacidad productiva de las fresadoras mediante la reducción del efecto del chatter utilizando actuadores inercia-les. XV. Congreso de Máquinas-Herramienta y Tecnologías de Fabricación, San Sebastián, Spain, October 20-22, 2004. [Sims 2007] Sims, N. D. Vibration absorbers for chatter suppression: A new analytical tuning methodology. Journal of Sound and Vibration, Vol. 31, pp. 592-607, 2007. [Tlusty 1957] Tlusty, J. and Polacek, M. Beispiele der behandlung der selb-sterregten Schwingung der Werkzeugmaschinen FoKoMa. Hanser Verlag, 1957, pp. 47-56. [Tobias 1958] Tobias, S. A. and Fishwick, W. Theory of regenerative machine tool chatter. The Engineer, February 1958, Vol. 205.


HSM2014–14013

INTEGRATION OF MACHINING MECHANISTIC MODELS INTO CAM SOFTWARE

J. A. Sarasua 1*, I. Cascón1

1IK4-TEKNIKER. ADVANCED MANUFACTURING TECHNOLOGIES. EIBAR, SPAIN


ABSTRACTDue to the increasing requirements of 5 axis machined products, collision simulation is not enough to ensure final quality. Hence, machining simulation models have been developed and commercialised in the last years. Mechanistic (semiempirical) models give approximate estimations of cutting forces during a whole tool path and, even not being very accurate, they are very useful to detect critical tool path steps, adapt cutting parameters or avoid machine overload. The main problem of these models is the fact that they work isolated from CAM programs and so, all the required information must be manually imported and refreshed.

[Kienzle 1957] Kienzle, O. and Victor, H., Spezifische Schnittkrafte bei der Metallbearbeitung, Werkstoffteechnik und Machinenbau. 1957, 47/5, pp. 224-225. [Armarego 1969] Armarego, E. J. A. and Brown, R. H., The Machining of Metals. 1969, Prentice-Hall. [Tuysuz 2013] Tuysuz, O., Altintas, Y. and Feng H. Y. Prediction of cutting forces in three and five-axisball-end milling withtool indentation effect, International Journal of Machine Tools & Manufacture 66 (2013) 66–81[Zatarain 2006] Zatarain, M., Munoa, J., Peigné, G. and Insperger, T. Analysis of the influence of mill helix angle on chatter stability. CIRP Annals-Manufactu-ring Technology 2006, 55 (1), 365-368[Sullivan 2012] Sullivan, A., Erdim, H., Perry, R. N. and Frisken, S. F., High accuracy NC milling simulation using composite adaptively sampled distance fields, Comput. Aided Des. (2012) 522-536. [Kaymakci 2008] Kaymakci M. andLazoglu, I., Tool path selection strategies for complex sculptured surface machining, Mach. Sci. Tecnhol. 12 (2008) 119–132. [Lee 2013] Lee, S. W., Kasten, A., Nestler, A. Analytic Mechanistic Cutting Force Model for Thread Milling Operations, 14th CIRP Conference on Modeling of Machining Operations (CIRP CMMO), Volume 8, 2013, Pages 546–551[Chérif 2004] Chérif, M., Thomas, H., Furet, B. and Hascoët, J. Y. Generic

Simulation; mechanistic; modelling; CAM integration

KEYWORDS

REFERENCES

This paper presents the integration of an open programmed mechanistic model into commercial CAM software. CAM simulates material removal process, while the model calculates and plots cutting efforts, power, vibrations and flank wear.The whole simulation is performed into CAM environment and any kind of change in the process (tool, material, tool path, cutting speed…) is automatically transferred to the mechanistic model. At the end, the user gets a CNC code that ensures not only collision avoidance, but also adequate process conditions.

modelling of milling forces for CAD/CAM applications, Int. J. Mach. Tools Manuf. 44 (2004) 29-37. [Li 2003] Li, Z. Z., Zheng, M., Zheng, L., Wu, Z. J. and Liu, D. C., A solid mo-del-based milling process simulation and optimization system integrated with CAD/CAM, J. Mater. Process. Technol. 138 (2003) 513-517. [Lamikiz 2005] Lamikiz, A., López de Lacalle, L. N., Sánchez, J. A. and Salgado, M. A. Cutting force integration at the CAM stage in the high-speed milling of complex surfaces, Int. J. Comput. Integr. Manuf. 18 (2005) 586-600. [Tunc 2009] L. T. Tunc, E. Budak, Extraction of 5-axis milling conditions from CAM data for process simulation, Int. J. Adv. Manuf. Technol. 43 (2009) 538-550. [Altintas 2000] Altintas, Y. Manufacturing Automation: Metal Cutting Mecha-nics Machine Tool Vibrations and CNC Design, Cambridge University Press, United Kingdom, 2000. [Erdim 2007] Erdim H., Lazoglu I. and Kaymakci M. Free- Form Surface Machi-ning and Comparing Feedrate Scheduling Strategies Machining Science and Technology, 2007Vol. 11, No. 1, pp. 117–133. [Holcombe 2013] Holcombe, S. http://www.mathworks.es/matlabcentral/fileexchange/37856-inpolyhedron--are-points-inside-a-triangulated-volume-


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HSM2014–14053

DERIVATION OF RECOMMENDATIONS FOR THE MANUFACTURING OF HIGH-SPEED REAMING TOOLS

T. Heep1, S. Güth1, A. Leong1

1TECHNISCHE UNIVERSITÄT DARMSTADT, INSTITUTE OF PRODUCTION MANAGEMENT TECHNOLOGY AND MACHINE TOOLS, DARMSTADT, GERMANY


ABSTRACTReamers are used widely in automotive manufacturing to guarantee high quality precision drilling. Typically, they are used in the machining of valve guides, found in cylinder heads of combustion engines. Reamers with multiple cutters are advantageous compared to reamers with only a single cutter because it reduces the reaming processing time. During the manufacture of reamers with multiple cutters, numerous disturbance factors due to manufacturing inaccuracies can arise. The sources of machining deficiencies (e. g. grinding error) are attributed to reasons which are machine, human-, environmental-, material- and method-related and are linked to errors in tool geometry which in turn affect the quality of reamed holes. In a previous study by Hauer, these machine deficiencies and tool geometrical errors are reclassified into five disturbance factors which include axial displacement, run-out error, slanted pre-drilled holes, grinding errors and angular errors. To enable a holistic evaluation of the quality of the drilled holes, dimensional, shape and surface parameters which include the diameter of enveloping cylinder,

[Defra 2007] Defra, Euras, EuroMetaux, ICMM: Metals Environmental Risk Assessment Guidance, MERAG Fact Sheet 07 Uncertainty Analysis, 2007. [Ekström 2006] Ekström, P. A., Broed, R. Sensitivity Analysis Methods and a Biosphere Test Case Implemented in EIKOS. Working Report. Technische Universität Darmstadt, 2006-31. [Frey 2001] Frey, H. C., Patil, S. R. Identification and Review of Sensitivity Analysis Methods, Civil Engineering Department, North Carolina University, 2001. [Hamby 1994] Hamby, D. M. Review of Techniques for Parameter Sensitivity Analysis of Environmental Models, Environmental Monitoring and Assess-ment 32, pp. 135 – 154, 1994. ISSN 0167-6369[Hauer 2012] Hauer, T. Modellierung der Werkzeugabdrängung beim Reiben-Ableitung von Empfehlungen für die Gestaltung von Mehrschnei-denreibahlen. PhD thesis. TechnischeUniversität Darmstadt, 2012. [Iman 1980] Iman, R. L., Conover, W. J. Small sample sensitivity analysis techniques for computer-models, with an application to risk assessment. communication in statistics-theory and methods 9 (17), pp. 1749 – 1842, 1980. [Iman 1987] Iman, R. L., Conover, W. J. A Measure of Top-Down Correlation, Technometrics, August 1987, Vol. 29, No. 3. ISSN 0040–1706[Jansen 1994] Jansen, M., Rossing, W., Daamen, R. Monte Carlo estimation of uncertainty contributions from several independent multivariate sources, J. Grasmanet. al. (eds), Predictability and nonlinear modelling in natural sciences and economics, 1994. ISSN 1364-8152[Lilburne 2009] Lilburne, L., Tarantola, S. Sensitivity Analysis of Spatial Models, International Journal of Geographical Information Science, Vol. 23, No. 2, February 2009, pp. 151 – 168. ISSN 1365-8816[Lund 2013] Lund Research Ltd: One Way ANOVA in SPSS, Laerd Statistics (2013) Available at https://statistics.laerd.com/spss-tutorials/one-way--anova-using-spss-statistics.php (Retrieved 25. 03. 2014). [Marino 2008] Marino, S., Hogue, I. B., Ray, C. J., Kirschner, D. E. A Methodology

Production process; drilling; montecarlo; simulation; reamingKEYWORDS

REFERENCES

average diameter of the drilled hole, average amount of circular error, average amount of cylinder error and surface roughness were defined. The analysis of how these input factors can affect the quality of reamed holes is complicated by the presence of uncertainties. Therefore, uncertainty analysis (UA) and sensitivity analysis (SA) methods are applied with the help of Monte Carlo simulation to account for the manufacturing uncertainties. The simulation results from UA indicate that variance of the output tool deflection increases with the increase in input variances while those from SA, specifically the most robust method eFAST (extended Fourier Amplitude Sensitivity Test), reveal the six most important input factors. Also, asymmetricity or skewness in the input probability distributions does not affect the output results. Lastly, the simulation results also show that limiting the input variances can help to increase accuracy of the output tool deflection. To ensure high manufacturing quality, manufacturers should thus seek to adhere to the new threshold limits which are defined for the input factors.

for Performing Global Uncertainty and Sensitivity Analysis in Systems Biology, Journal of Theoretical Biology 254, pp. 178 – 196, 2008. ISSN 0022-5193[Mckay 1995] Mckay, M. D. Technical Report NUREG/CR-6311, LA–12915-MS, US Nuclear Regulatory Commission and Los Alamos National Labo-ratory, Washington D. C., 1995. ISSN 1029-0311[Mokhtari 2005] Mokhtari, A., Frey, H. C. Sensitivity Analysis of a Two--Dimensional Probabilistic Risk Assessment Model using Analysis of Vari-ance, Risk Analysis, Vol. 25, No. 6, 2005. ISSN 0272-4332[Ross 2006] Ross, S. M. Simulation, Fourth Edition, 2006. [Rubinstein 2008] Rubinstein, R. Y., Kroese, D. P. Simulation and the Monte Carlo Method, 2nd edition, Wiley-Interscience, 2008. ISSN 1387-5841[Saltelli 1999] Saltelli, A., Tarantola, S., Chan, K. P. S. A Quantitative Model--Independent Method for Global Sensitivity Analysis of Model Output, Joint Research Centre of the European Commission, Technometrics, February 1999, Vol. 41, No. 1. ISSN 0040–1706[Saltelli 2006] Saltelli, A., Chan, K. and Scott, E. M. Sensitivity Analysis. Wiley Series in Probability and Statistics, 2006. ISBN 9780471998921[Saltelli 2010] Saltelli, A., Annoni, P., Azzini, I., Campolongo, F., Ratto, M., Tarantola, S. Variance-Based Sensitivity Analysis of Model Output. Design and Estimator for the Total Sensitivity Index, Joint Research Centre of the European Comission, Institute for the Protection and Security of the Citi-zen, Ispra, Italy, Computer Physics Communications 181, pp. 259 – 270, 2010. ISSN 0010-4655[Tang 2007] Tang, Y., Reed, P., Wagener, T., Werkhoven, K. V. Comparing sensitivity analysis methods to advance lumped watershed model identifi-cation and evaluation, Hydrology Earth System Sciences, 11, pp. 793 – 817, 2007. ISSN 1027-5606[Zi 2011] Zi, Z. Sensitivity analysis approaches applied to systems biology models, IET System Biology, 2011, Vol. 5, Iss. 6, pp. 336 – 346. ISSN 1751-8849


HSM2014–14084

CUTTING TOOL DEVELOPMENTFOR EFFECTIVE MILLING OF TI6AL4V

P. Zeman1*, J. Malý1



ABSTRACTCutting tools are exposed to very hard conditions in the milling of titanium alloys. Poor thermal conductivity of the work material as well as a high mechanical load on the cutting edge lead to short tool life, low tool performance, and poor cost-effectiveness of the process. Since insufficient cooling of the process is used in many cases, only low cutting speeds are applicable. The main scope of the research was to develop and fully test a new cutting tool made of coated cemented carbide for the end milling of titanium alloys and other difficult-to-cut materials. It was possible to prepare a more positive geometry of the new tool owing to smaller helix angles. The effect of the tool tip chamfer and carbide substrate on results were observed. The new tool was tested under various cutting conditions (cutting speed, feed) and using different cooling methods (external, through the spindle). The properties of the tool were observed

[Ahmad 2007] Ahmad, F. I. et. al. Effectiveness of uncoated WC–Co and PCD inserts in end milling of titanium alloy—Ti–6Al–4V. Journal of Materials Processing Technology, October 2007, Vol. 192–193, pp. 147–158. ISSN 0924-0136[Arrazola 2009] Arrazola, P. J., et al. Machinability of titanium alloys (Ti6Al4V and Ti555. 3). Journal of Materials Processing Technology, March 2009, Vol. 209, pp. 2223-2230. ISSN 0924-0136[Bach 2012] Bach, P., et al. High Performance Titanium Milling at Low Speed. In: Proceedings of 5th CIRP International Conference on High Performance Cutting, Zurich, 2012. ETH Zurich, pp. 226–231. [Jawaid 2000] Jawaid, A., et al. Evaluation of wear mechanisms of coated car-

Cutting tool; milling; titanium alloy; performance; costKEYWORDS

REFERENCES

and analyzed from various points of view, including tool life, tool performance and cost-effectiveness. A new methodology for the calculation of manufacturing costs was applied. The research has shown that in spite of the higher price of the improved cutting tool, the tool allows higher removal rates of material at similar or lower manufacturing costs as the standard tool. Using of the tool resulted in higher productivity and better cost-effectiveness in milling of Ti6Al4V alloy. The new tool allowed a decrease in the manufacturing costs of up to 30% and at the same time an increase in the productivity of 33% compared to the commercial tool at a cutting speed of 50 m/min. The lowest manufacturing costs were achieved at a speed of 43 m/min. It was a decrease in the range of 14 to 18 % (according to the type of machine tool) from the minimal costs for the commercial tool.

bide tool when face milling titanium alloy. Journal of Materials Processing Technology, March 2000, Vol. 99, pp. 266-274. ISSN 0924-0136[Madl 2008] Madl, J., Zeman, P. Milling of Ti6Al4V Alloy with Sintered Carbide Tools. In: Proceedings of the 3rd International Conference on Manufacturing Engineering. Thessaloniki, 2008, Aristoteles University of Thessaloniki, Me-chanical Engineering Dept., LABORATORY FOR MACHINE TOOLS & MANU-FACTURING ENGINEERING, pp. 155–164. [Palanisamy 2009] Palanisamy, S., et al. High Pressure Coolant Application in Milling Titanium. In: Materials Science Forum, Switzerland, 2009. Vols. 618-619, pp. 89–92. [Schulz 1992] Schulz, H., Moriwaki, T. High-Speed Machining. Annals of the CIRP, 1992, Vol. 41, No. 2, pp. 637-643. ISSN 0007-8506.


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HSM2014–14090

MATERIAL SPECIFIC CUTTING EDGE GEOMETRIESFOR MACHINING PROCESSES

B. Denkena1, T. Grove1, M. Rehe1*, B. Bergmann1

1IFW, INSTITUTE OF PRODUCTION ENGINEERING AND MACHINE TOOLS, LEIBNIZ UNIVERSITÄT HANNOVER, GARBSEN, GERMANY


ABSTRACTDuring machining a high thermo-mechanical load results at the cutting edge. This load depends on the physical and mechanical properties of the workpiece material and machining parameters, which determines the tool life and wear behavior. Due to the shape of the cutting edge the wear behavior and thus the tool life and machining performance can be influenced decisively. This paper deals with influence of rounded cutting edges and modified flank face modifications, which leads to geometrical limitation of the flank wear, on wear behavior. The preparation of rounded cutting

Paper in a journal: [Aurich 2011] Aurich, J. C., Zimmermann, M., Leitz, L. The preparation of cutting edges using a marking laser. Prod. Eng. Res. Devel. Vol. 5, pp. 17-24, 2011[Bassett 2012] Bassett, E., Koehler, J., Denkena, B. On the honed cutting edge and its side effects during orthogonal turning operations of AISI1045 with coated WC-Co inserts, CIRP J. of Manuf. Sci. and Techn., Vol. 5, pp. 108 – 126, 2012[Ber 1982] Ber, A., Kaldor, S. The First Seconds of Cutting, Wear Behaviour, Annals of the CIRP Vol. 31/1, 1982, pp. 13–17[Biermann 2008] Biermann, D., Terwey, I. Cutting edge preparation to improve drilling tools for HPC processes. CIRP Journal of Manufacturing Science and Technology 1, pp. 76–80, 2008[Bouzakis 2009] Bouzakis, K. -D., Gerardis, S., Katirtzoglou, G., Makrimallakis, S., Bouzakis, A., Cremer, R., Fuss, H. -G. Application in milling of coated tools with rounded cutting edges after the film deposition. CIRP Annals – Manu-facturing Technology 58, pp. 61–64, 2009[Breidenstein 2014] Breidenstein, B., Gey, C., Denkena, B. Residual Stress Development in Laser Machined PVD-Coated Carbide Cutting Tools, Materials Science Forum, Vols. 768-769, pp. 391-397, 2014[Denkena 2011] Denkena, B., Koehler, J., Meyer, R., Stiffel, J. -H. Modificati-on of the Tool-Workpiece Contact Conditions to Influence the Tool Wear and Workpiece Loading During Hard Turning, International Journal of Automation Technology, Vol. 5, No. 3, pp. 353-361, 2011[Denkena 2012a] Denkena, B., Breidenstein, B., Wagner, L., Wollmann, M., Mhaede, Mansour. Influence of shot peening and laser ablation on residual stress state and phase composition of cemented carbide cutting inserts, Int. Journal of Refractory Metals and Hard Materials, No. 7, pp 85-89, 2012[Wyen 2011] Wyen, C. F., Knapp, W., Wegener, K. A new method for the cha-racterization of rounded cutting edges. The International Journal of Advanced Manufacturing Technology, Online First™, 2 September 2011[Denkena 2014] Denkena, B., Biermann, D. Cutting edge geometries. CIRP Annals Manufacturing Technology, http://dx. doi. org/10. 1016/j. cirp. 2014. 05. 009, 2014

Paper in proceedings: [Denkena 2013] Denkena, B., Köhler, J., Breidenstein, B., Bergmann, B. Influ-ence of Laser Ablation on Wear Behavior of cBN Cutting Inserts, Euro PM2013,

Cutting edge rounding; flank face modification; machining; wearKEYWORDS

REFERENCES

edges was conducted by means of abrasive brushing. The flank face modification was done by laser machining. The challenge of both approaches is to design the cutting edge with respect to the material. Therefore, the wear behavior with regard to the cutting edge and the material properties are discussed. In addition, this paper presents the influence of the laser machining process parameters on the performance of the flank face modifications. With the developed cutting edge geometries an increased tool life of 100 % was achieved.

congress & Exhibition, Proceedings Volume 1 – Diamant Tools. pp. 75-81, 2013[Denkena 2005] Denkena B, Reichstein M, Brodehl J, de León García L. Sur-face Preparation, coating and wear performance of geometrically defined cutting edges. Proceedings of the 5th International Conference “THe Coatings” in Manufacturing Engineering, 5-7; October 2005[Denkena 2010] Denkena, B., de Leon, L., Bassett, E., Rehe, M. Cutting Edge Preparation by Means of Abrasive Brushing. 8th Int. Conf. "THE Coatings" in Manuf. Eng., Erlangen, Germany, April 14 – 15, Key Eng. Materials, 438, pp. 1 – 7, 2010[Denkena 2012b] Denkena, B., Koehler, J., Rehe, M. Influence of the Honed Cutting Edge on Tool Wear and Surface Integrity in Slot Milling of 42CrMo4 Steel. 5th CIRP Conference on High Performance Cutting, 4-7th June, Proce-dia CIRP 1, 190 – 195 pp. 196 – 201, 2012[Machado 1990] Machado, A. R., Wallbank J. Machining of titanium and its alloys—a review. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 204, No. 1, pp. 53-60, 1990[Tönshoff 2003] Tönshoff, H. K., Ostendorf, A., Kulik, C., Siegel, F. Finishing of Cutting Tools using Selective Material Ablation. Proceedings of the 1st Int. CIRP Seminar on Micro and Nano Technology, Copenhagen, Denmark, pp. 77 – 80, 2003

Technical reports or thesis: [Bassett 2014] Bassett, E. Belastungsspezifische Aus-legung und Herstellung von Schneidkantengeometrien für Drehwerkzeuge. Dr. -Ing. Diss., Leibniz Uni-versität Hannover, 2014[Cortés 2009] Cortés Rodriguez, C. J. Cutting edge preparation of precision cutting tools by applying micro-abrasive jet machining and brushing. Disserta-tion, Universität Kassel, 2009[DIN 2012] DIN 32540 Laserstrahlabtragen – Thermisches Abtragen mit dem Laserstrahl – Begriffe, Einflussgrößen, Durchführung. German Industry Stan-dard, 2012[Klocke 2008] Klocke, F., König W. Fertigungsverfahren 1: Drehen, Fräsen, Bohren. 8. Auflage. Springer, Berlin, 2008[Spittel 2009] Spittel, M., Spittel, T. Steel symbol/number: X40CrMoV5–1/1. 2344. Warlimont, H. (ed.). Springer Materials – The Landolt-Börnstein Data-base, Springer-Verlag, http://www. springermaterials.com, Berlin Heidelberg, 2009[Toolox] Product sheet: Toolox®44, 450 HBW (~45 HRC). www.Toolox.com


HSM2014–14011

TURBINE BLADE MACHINING BY USE OF CARBON DIOXIDE AS CRYOGENICS

T. Schaarschmidt1*, S. Cordes1, F. Hübner1

1WALTER AG, TÜBINGEN, GERMANY


ABSTRACTIn this paper, a new approach to use liquid carbon dioxide as cryogenic media in turbine blade machining of martensitic and austenitic stainless steels such as X22CrMoV12–1 (1. 4923) and X12CrNiWTiB16–13 (1. 4962) is presented. To enhance the cutting performance when machining materials likes this, cryogenic machining can be one option. The new approach is characterized by a new way of supplying liquid CO2 through a multi-channel internal supply system into the cutting zone. Therefore, an adapted

[Hong 2001] Hong, SY, Markus, I, Jeong, W. New cooling approach and tool life improvement in cryogenic machining of titanium alloy Ti-6Al-4V. Int J Machine Tool & Manufacture 2001; 41: 2245-2260. [Yildiz 1972] Yildiz, Y, Nalbant, M. Procedures and Precautions in Machining Titanium Alloys. In: Titanium Science and Technology. Proceedings of the Second International Conference, Cambridge, 2-5 May 1972. p. 489-504. [Khan 2008] Khan, A. A., Ahmed, MI. Improving tool life using cryogenic cooling, J of Mat Proc Tech, 2008; 196: 149–154. [Klocke 2012] Klocke, F., Krämer, A., Sangermann, H., Lung, D. Thermo-Me-chanical Tool Load during High Performance Cutting of Hard-to-Cut Materi-als, Procedia CIRP, 2012; 1: 312-317.

Cryogenic machining; milling; cutting toolKEYWORDS

REFERENCES

machine tool, a special rotary feed trough and adapted tools were developed. Focus of the studies has been the applicable cutting data, cutting tool wear, surface quality and chip formation. The studies show high potential for carbon dioxide as cryogenic media. On the one hand, the cutting performance could be enhanced by 70 %, on the other hand tool wear rate could be reduced by 63 %. Positive effects could also be seen on chip formation and workpiece surface quality.

[Kronenberg 1954] Kronenberg, M. Grundzüge der Zerspanungslehre. 1st ed. Berlin: Springer, 1954[Vieregge 1953] Vieregge, G. Die Energieverteilung und die Temperatur bei der Zerspanung. Werkstatt und Betrieb 1953; 86: 691-703[Vieregge 1955] Vieregge, G. Temperaturfeld und Wärmebilanz des Schervor-ganges bei der Zerspanung. Werkstatt und Betrieb 1955; 88: 227-230[Pušavec 2011] Pušavec, F., Kopač, J. Sustainability Assessment: Cryogenic Machining of Inconel 718. J. Mech. Eng. 2011; 57: 637-647.


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HSM2014–14035

THE INFLUENCE OF HIGH-PRESSURE LUBRICOOLANT SUPPLY VARIANT ON CUTTING PERFORMANCE IN TURNING OF 42CRMO4+QTF. Klocke1, D. Lung1, T. Cayli1*

1RWTH AACHEN, LABORATORY FOR MACHINE TOOLS AND PRODUCTION ENGINEERING, WZL, AACHEN, GERMANY


ABSTRACTIn the field of machining difficult-to-cut materials like quenched and hardened steels, titanium or nickel-based alloys, the use of a high-pressure lubricoolant supply may result in a significant increase of productivity and process stability. Due to enhanced cooling and lubrication of the cutting zone and thus reduced thermal tool load, tool wear can be decreased which allows higher applicable cutting speeds. Furthermore, the process stability can be increased as a result of effective chip breaking and chip evacuation. The present paper investigates the effect of high-pressure lubricoolant supply variants (onto the flank face, onto the rake face and the combined supply onto the flank and rake face of the tool) in an external longitudinal turning of 42CrMo4+QT (S < 0. 01 %) with cemented carbide tools.

[Braham 2009] Braham, T., Germain, G., Robert, R.; Lebrun, J. L., Auger, S. High-pressure water jet assisted machining of duplex steel: Machinability and tool life. 12th CIRP Conference on Modelling of Machining Operations, Donos-tia-San Sebastiân, Spanien, 7. -8. Mai 2009. [Choudhury 1998] Choudhury, I. A., and El-Baradie, M. A. Machinability of nic-kel-base super alloys: a general review. In: Journal of Materials Processing Technology, 1998, Vol. 77, pp. 278-284. [Crafoord 1999] Crafoord, R., Kaminski, J., Lagerberg, S., Ljungkrona, O., Wret-land, A. Chip control in tube turning using a high-pressure water jet. In: Proc. IMechE Part B, 1999, Vol. 213, No. 8, pp: 761-767. [Crafoord 1999] Crafoord, R., Kaminski, J., Lagerberg, S., Ljungkrona, O. and Wretland, A. Chip control in tube turning using a high-pressure water jet. In: Proc. IMechE Part B, 1999, Vol. 213, pp. 761-767. [Dudzinski 2004] Dudzinski, D., Devillez, A., Moufki, A., Larrouwuère, D., Ze-rrouki, V. and Vigneau, J. A review of developments towards dry and high spe-ed machining of Inconel 718 alloy. In: International Journal of Machine Tools & Manufacture, 2004, Vol. 44, pp. 439-456. [Ezugwu 1990] Ezugwu, E. O., Machado, A. R., Pashby, I. R., Wallbank, J. The Effect of High-Pressure Coolant Supply When Machining a Heat-Resistant Nickel-Based Superalloy. In: Lubrication Engineer, 47 (1990) pp. 751-757. [Ezugwu 2004] Ezugwu, E. O., Bonney, J. Effect of high-pressure coolant supp-ly when machining nickel-base, Inconel 718, alloy with coated carbide tools. In: Journal of Materials Processing Technologie, 153–154 (2004) 1045–1050. [Ezugwu 2005] Ezugwu, E. O. Key improvements in the machining of difficult--to-cut aerospace superalloys. International Journal of Machine Tools & Ma-nufacture, 2005, Vol. 45, pp. 1353–1367. [Kaminski 2000] Kaminski, J., Alvelid, B. Temperature reduction in the cutting zone in water-jet assisted turning, Journal of Materials Processing Technolo-gy, 2000, 106: 68-73. [Kaminsky 2000] Kaminsky, J., Ljungkrona, O., Crafoord, R., and Lagerberg. S.

High-pressure lubricoolant supply; jet-assisted cutting; high-pressure cooling; turning; tool temperature; jet guidance geometry; high-pressure lubricoolant supply variant; steel

KEYWORDS

REFERENCES

The cutting tool temperature, tool wear, surface roughness and resulting chip forms were analyzed for different lubricoolant supply variants using tools with specially designed lubricoolant jet guidance geometry on the rake face for an effective supply of the coolant to the cutting edge and conventional tools with a chip breaker geometry. To study the effect of high-pressure lubricoolant supply variant and jet guidance geometry on tool temperature, reference tests also carried out using conventional flood cooling. The results suggest that the tool temperature can be decreased by almost 49 per cent compared to conventional flood cooling by applying the combined supply variant (lubricoolant supply onto the rake and flank face) and using specially designed jet guidance geometry.

Control of chip flow direction in high-pressure water jet-assisted orthogonal tube turning. In: Journal of Materials Processing Technology, 2000, Vol. 214, pp. 529-534. [Khan 2008] Khan, A. A., Ahmed, M. I. Improving tool life using cryogenic coo-ling. In: Journal of Materials Processing Technology., 196 (2008) 149–154. [Klocke 2010] Klocke, F., Lung, D., Essig, C. and Sangermann, H. Automati-sierte Produktion – ohne Spanbruch undenkbar. In: Zeitschrift für wirtschaft-lichen Fabrikbetrieb ZWF, Carl Hanser Publishing, Munich, 2010, Vol. 105 1-2, pp. 21-25. [Klocke 2011] Klocke, F., Sangermann, H., Krämer, A. and Lung, D. Influence of a high-pressure lubricoolant supply on thermo-mechanical tool load and tool wear behaviour in the turning of aerospace materials, Proc. IME B J. Eng. Ma-nufact., 225/1 (2011) pp. 52-61. [Klocke 2013] Klocke, F., Lung, D., Cayli, T., Sangermann, H., Krämer, A. Po-tential of Modern Lubricoolant Strategies on Cutting Performance, Key Engi-neering Materials, 554-557 (2013) 2062-2071. [Machado 1994] Machado, A. R. and Wallbank, J. The effects of a high-pressure coolant jet on machining. In: Proc. IMechE, 1994, Vol. 208, pp. 29-38. [Mazurkiewicz 1989] Mazurkiewicz, M., Kubala, Z., Chow, J. Metal Machining With High-Pressure Water-Jet Cooling Assistance – A New Possibility. In: Journal of Engineering for Industry, 111/7 (1989). [Palanisamy 2009] Palanisamy, S., McDonald, S. D., Dargusch, M. S. Effects of coolant pressure on chip formation while turning Ti6Al4V alloy, International Journal of Machine Tools and Manufacture. 2009, Vol. 49, pp. 739-743. [Sangermann 2013] Sangermann, H. Hochdruck-Kühlschmierstoffzufuhr in der Zerspanung, Apprimus Verlag, Aachen. 2013[Sharmann 2008] Sharman, A. R. C., Hughes, J. I. and Ridgway, K. Surface integrity and tool life when turning Inconel 718 using ultra-high-pressure and flood coolant systems. In: Proc. IMechE, 2008, Vol. 222 Part B: J. Engineering Manufacture, pp. 653-664.


HSM2014–14065

AN EXPERIMENTAL INVESTIGATION OF FRICTION AND CUTTING MECHANICS UNDER THE MQL AND MQL+CO2 CONDITIONS

K. Rahimzadeh Berenji1*, A. T. Kuzu1, M. Bakkal1

1ISTANBUL TECHNICAL UNIVERSITY, FACULTY OF MECHANICAL ENGINEERING, ISTANBUL, TURKEY


ABSTRACTRecently, Minimum Quantity Lubrication (MQL) became drastically demanding method due to its cost wise efficiency and eco-friendly aspect in machining. Moreover, MQL also enhances the friction behavior on tool-chip contact zone on rake face of tool. This study presents an experimental approach to analyze the stick-slip mechanism at the tool rake face in the presence of MQL during machining experiments. The relationships between sliding and overall friction coefficients have been studied. The sliding and apparent friction coefficient derived from orthogonal tube cutting tests. Orthogonal cutting tests were conducted in case of identifying sliding friction coefficient under dry and MQL and MQL+CO2 conditions. Moreover, orthogonal cutting tests were also run for measuring the tool-chip contact length. Data obtained from the contact length measurements under different conditions

Paper in a journal: [Dhar 2006] Dhar, N. R., Kamruzzaman, M., Mahiuddin Ahmed, Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel, Journal of Materials Processing Technology, Volu-me 172, Issue 2, 28 February 2006, Pages 299-304, ISSN 0924-0136[Childs 2006] Childs, T. H. C., Friction modelling in metal cutting, Wear, Volume 260, Issue 3, 10 February 2006, Pages 310-318, ISSN 0043–1648 [Budak 1996] Budak, E., Armarego, E. J. A., & Altintas, Y. (1996). Prediction of milling force coefficients from orthogonal cutting data. Journal of engi-neering for industry, 118(2), 216-224. [Klocke 1997] Klocke, F., Eisenblätter G., Dry Cutting, CIRP Annals – Ma-nufacturing Technology, Volume 46, Issue 2, 1997, Pages 519-526, ISSN 0007-8506 [Leppert 2010] Leppert, T., Effect of cooling and lubrication conditions on surface topography and turning process of C45 steel, International Journal of Machine Tools and Manufacture, Volume 51, Issue 2, February 2011, Pages 120–126, ISSN 0890-6955[Li 2007] Li ,K. -M, Liang, S. Y. Modeling of cutting forces in near dry machi-ning under tool wear effect, International Journal of Machine Tools and Manu-facture, Volume 47, Issues 7–8, June 2007, Pages 1292–1301, ISSN 0890-6955[Ozlu 2007] Ozlu, E., Budak, E., Molinari, A. Thermo mechanical modeling oforthogonal cutting including theeffect of stick-slide regions on the rake face, 10thCIRP International Workshop on Modeling of Machining Operati-ons, Calabria, Italy, August2007[Ozlu 2009] Ozlu, E., Budak, E., Molinari, A. Analytical and experimental investigation of rake contact and friction behavior in metal cutting, Inter-national Journal of Machine Tools and Manufacture, Volume 49, Issue 11, September 2009, Pages 865-875, ISSN 0890-6955[Supekar 2012] Supekar, S. D., Clarens, A. F., Stephenson, D. A., Skerlos, S.

Cutting mechanics; MQL; MQL+CO2; friction coefficientKEYWORDS

REFERENCES

are compared. Contact length behavior has been compared in different feed and cutting velocity values. Furthermore, friction and dual zone behavior during orthogonal cutting at different cooling conditions and cutting velocities investigated using mechanistic approach. Results of study showed that lower sliding friction coefficients can be determined while using MQL and MQL+ CO2. This can be attributed to cooling and lubrication effect of MQL media during metal cutting which changes the chip contact behavior on rake face of tool. Reduction of sliding friction coefficient causes lower contact length behavior at tool/chip interface which will decrease tool wear at rake face of tool. Moreover, edge force coefficients have been studied at different conditions and cooling conditions and reduction observed at edge force values while using MQL cooling media.

J. Performance of supercritical carbon dioxide sprays as coolants and lub-ricants in representative metalworking operations, J. of Mat. Proc. Tech., Volume 212, Issue 12, December 2012, Pages 2652-2658, ISSN 0924-0136[Tawakkoli 2001] Tawakoli, T., Hadad, M. J., Sadeghi, M. H. Investigation on minimum quantity lubricant-MQL grinding of 100Cr6 hardened steel using different abrasive and coolant–lubricant types, International Journal of Ma-chine Tools and Manufacture, Volume 50, Issue 8, August 2010, Pages 698-708, ISSN 0890-6955[Tasdelen 2008] Tasdelen, B., Thordenberg, H., Olofsson, D. An experimen-tal investigation on contact length during minimum quantity lubrication (MQL) machining, Journal of Materials Processing Technology, Volume 203, Issues 1–3, 18 July 2008, Pages 221-231, ISSN 0924-0136[Sadeghi 2009] Sadeghi, M. H., Haddad, M. J., Tawakoli, T., Emami, M. Mi-nimal quantity lubrication-MQL in grinding of Ti-6Al-4V titanium alloy, International Journal of Advanced Manufacturing Technology, 44 (2009), pp. 487–500[Sharma 2009] Sharma, S., Manu Dogra, Suri, N. M. Cooling techniques for improved productivity in turning, International Journal of Machine Tools and Manufacture, Volume 49, Issue 6, May 2009, Pages 435-453, ISSN 0890-6955[Weinert 2004] Weinert, K., Inasaki, I., Sutherland, J. W., Wakabayashi, T. Dry Machining and Minimum Quantity Lubrication, CIRP Annals – Manufacturing Technology, Volume 53, Issue 2, 2004, Pages 511-537, ISSN 0007-850[Zorev 1963] Zorev, N. N. Inter-relationship between shear processes occu-rring along tool face and shear plane in metal cutting. International Re-search in Production Engineering, 1963, 49.

Technical reports or thesis: [Altintas 2011] Altintas, Y. Manufacturing Automation. Cambridge: Cam-bridge University Press, 2011. ISBN 978–1–107-00148-0


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HSM2014–14080

EVALUATION OF CARBIDE TOOL PERFORMANCED UNDER CONVENTIONAL COOLANT AND ALTERNATIVE MINIMAL QUANTITY LUBRICATION IN HIGH SPEED TURNING TI-6AL-4V ELIM. A. Sulaiman1*, C. H. Che Haron2, J. A. Ghani2, M. S. Kasim1, E. Mohamad1

1DEPARTMENT OF PROCESS, FACULTY OF MANUFACTURING ENGINEERING, UNIVERSITI TEKNIKAL MALAYSIA MELAKA, 76100, MALAYSIA2DEPARTMENT OF MECHANICAL AND MATERIAL ENGINEERING, FACULTY OF ENGINEERING AND BUILD ENVIRONMENT, UNIVERSITY OF NATIONAL MALAYSIA,43600 BANGI, SELANGOR, MALAYSIA


ABSTRACTThe study to evaluate the tool life performance of uncoated carbide tool, CNGG 120408-SGF-H13A, and the quality of machined surface, focusing on roughness surface values in turning titanium alloy, Ti-6Al-4V extra low interstitial (ELI), under minimal quantity lubrication (MQL) and conventional coolant. High cutting speed values were applied during the finish turning of titanium alloy. The cutting parameters were arranged using the Box-Behnken design experiment. Meanwhile the cutting parameters; cutting speed (120, 170, and 220 m/min), feed rate (0. 1, 0. 15, and 0. 2 mm/rev), and

[Che-Haron 2005] Che-Haron, C. H., and Jawaid, A. The effect of machining on surface integrity of titanium alloy Ti-6%Al-4%V. Journal of Materials Proce-ssing Technology, 2005, 166 188–192. [Che Haron 2001] Che Haron, C. H., Ginting, A. and Goh, J. H. Wear of coated and uncoated carbides in turning tool steel. Journal of Materials Processing and Technology, 2001, 116, 49-54. [Che Haron 2001] Che Haron, C. H. Tool life and surface integrity in turning tita-nium alloy. Journal of Material Processing and Technology, 2001, 118, 231-237. [Ezugwu 2005] Ezugwu, E. O. Key improvement in the machining of difficult-to--cut aerospace superalloys. International Journal of Machine Tools & Manu-facture, 2005, 45, 1353–1367. [Ezugwu 2003] Ezugwu, E. O., Booney, J., and Yamane, Y. An overview of the machinability of aeroengine alloys. Journal of Material Processing and Tech-nology, 2003, 134, 233-253. [Ezugwu 1997] Ezugwu, E. O., and Wang, Z. M. Titanium alloys and their machinability – A review. Journal of Material Processing and Technology, 1997, 68, 262-274. [Ibrahim 2009] Ibrahim, G. A., Che Haron, C. H., and Ghani, J. A. Progression and Wear Mechanism of CVD Carbide Tools in Turning Ti-6Al-4V ELI. Interna-tional Journal of Mechanical and Materials Engineering (IJMME), 2009, 4 (1), 35-41. [Gusri et al. 2008] Gusri, A. I., Che Hassan, C. H., Jaharah, A. G. The effect of dry machining on surface integrity of titanium alloy Ti-6Al-4V ELI. Journal of Applied Science, 2008, 1, 121–127. [Abdel 2009] Abdel, H. A., Nouri, M. and El-Mansori, M. Influence of thermal conductivity on wear when machiningtitanium alloys. Tribology International, 2009, 42 (2) 359 – 372. International

High speed turning; Ti-6Al-4V ELI; minimal quantity lubrication (MQL); conventional coolant; uncoated carbideKEYWORDS

REFERENCES

depth of cut (0. 4, 0. 5, and 0. 6 mm) were applied. The effects of two types of coolant were observed and the results shown that the cutting tool turned under MQL has a longer tool life (25%) and leads to reduce surface roughness of machined surface (30%) compared with that turned under the conventional coolant condition. It was identified that the MQL condition is a good alternative in replacing the conventional coolant. Additionally with proper conducted, MQL can be uses in all machining processes thereby not only environmental friendly but also improve the machinability performances.

Standard Organization. 1993. Tool Life Testing with Single-point Turning Tools. International Standard Organization ISO 3685. [Jawaid et al. 1999] Jawaid, A., Che Haron, C. H., Abdullah, A. Tool wear cha-racteristics in turning of titanium alloy Ti-6246. Journal of Material Processing and Technology, 1999, 92, 329-334. [Jawaid et al. 2000] Jawaid, A., Sharif, S., Koksal, S. Evaluation of wear mecha-nism of coated carbide tools when face milling titanium alloy. Journal of Mate-rial Processing and Technology, 2000, 99, 266-274. [Kalpakjian and Rchmid 2001] Kalpakjian, S., Rchmid, S. R. 2001. Manufactu-ring Engineering and Technology. 3rd ed. Prentice Hall: Pearson[Sulaiman et al. 2012] Sulaiman, M. A., Che Haron, C. H., Ghani, J. A., and Kasim, M. S. The Study Of Wear ProcessOn Uncoated Carbide Cutting Tool In Machining Titanium Alloy. Journal of Applied Sciences Research, 2012, 8(9), 4821-4827. [Dhar et al. 2006] Dhar, N. R., Islam, M. W., Islam, S. and Mithu, M. A. H. The in-fluence of minimum quantity of lubrication (MQL) on cutting temperature, chip, and dimensional accuracy in turning AISI–1040 steel. Journal of Materials Pro-cessing Technology, 2006, 171 93-99. [Narutaki and Yamane 1993] Narutaki, N. and Yamane, Y. Machining of diffi-cult-to-cut materials. International Journal of Japan Society Precision Engi-neering, 1993, 27 (4), 307-310. [Sreejith and Ngoi 2008] Sreejith, P. S. and Ngoi, B. K. A. Dry machining of the future. Journal of Material Processes Technology, 2008, 101 (1-3), 289-293. Trent, E. M., 1995. Metal Cutting, Third Edition. Butterworth-Heinemann, Oxford. [Venkatesh 1980] Venkatesh, V. C. Tool wears investigations on some cutting tool materials. Journal of Lubrication Technology, 1980, 102, 556-559.


HSM2014–14031

EXPERIMENTAL INVESTIGATION IN MICRO-BALL-END MILLING OF HARDENED STEEL

B. Escolle1*, M. Fontaine1, S. Thibaud1, P. Picart1

1FEMTO-ST INSTITUTE, DEPARTMENT OF APPLIED MECHANICS, UMR CNRS 6174/UFC/ENSMM/UTBM, 24 CHEMIN DE L'EPITAPHE, 25000 BESANÇON, FRANCE


ABSTRACTThe increase in demand for micro-components needs the control of associated micro-manufacturing processes. Among existing processes, micro-milling appears to be the most versatile. From a down-scaling of conventional machining, micro-milling can be defined by the use of tools which have a diameter between a dozen microns and 1 millimeter. It presents the advantage to be applicable to a wide range of materials and to allow shaping pieces having a complex 3D geometry and relatively high shape ratios. However, miniaturizing the process amplifies the impact of several phenomena which are often overlooked or simplified when considering conventional machining. Many industries are already users of micro-milling techniques, but are confronted with the lack of knowledge of this process. Scientific studies dealing with micro-machining are recent and focus mainly on the phenomenological modeling of micro-cutting and the influence of scale effects in a "top-down" optimization approach. This paper presents a study focused on machining of hardened steel (54/55HRC), typically used for the production of plastic

[Masuzawa 1997] Masuzawa, T. and Tonshoff, H. K. Three-dimensional micro-machining by machine tools, Annals of the CIRP, 1997, Vol. 46, No. 2, pp 621-628. [Freidrich 1997] Friedrich, C. R., Coane, P. J., and Vasile, M. J. Micro milling de-velopment and applications for micro fabrication, Journal of Microelectronic Engineering, 1997, Vol. 35, pp 367-372. [Gilbin 2013] Gilbin, A., Fontaine, M., Michel, G., Thibaud, S. and Picard, P. Capability of tungsten Carbide Micro-mills to machine hardened tool steel, International journal of precision engineering and manufacturing, 2013, Vol. 14, Issue 1, p 23-28. [Simoneau 2006] Simoneau, A., Ng, E., Elbestawi, M. A. Chip formation during micro scale cutting of a medium carbon steel, International Journal of Machi-ning Tools and Manufacture, 2006, Vol. 46, pp 467-481. [Bissaco 2005] Bissaco, G., Hansen, H. N. and De Chiffre, L. Micromilling of hardened tool steel for mould making applications, Journal of Materials Processing Technology, 2005, Vol. 167, pp 201-207. [Toh 2004] Toh, CK, A study of the effets of cutter path strategies and orienta-

Micro-milling; ball-end milling; tungsten carbide; hardened steel; PVD coatingKEYWORDS

REFERENCES

injection molds, with 0. 5 mm diameter micro-ball-end mills made from micro-grain tungsten carbide and PVD coated. The efficiency of micro-milling cutters selected from different manufacturers has been tested for different machining conditions. Some phenomena related to the micro-milling process have been highlighted from the obtained experimental data based on in-time measurements and post-observations. It is thus illustrated the influence of tool characteristics and cutting conditions on generated cutting forces, surfaces quality and tool wear, following three main axes of influence: machined material, geometry and carbide / coating couple of the tool. For example, the importance of selecting the appropriate carbide / coating couple is demonstrated through its influence on coating grip and abrasion wear. The influence of tool geometry is more difficult to analyze but is more discriminating for flat machining (no tool/surface inclination). Finally, dynamic instabilities in tool behavior are identified and discussed, especially when considering that a varying tool/surface angle induces evolution in resulting depths of cut.

tions in milling, Journal of Materials Processing Technology, 2004, Vol. 152, pp346-356. [Fontaine 2007] Fontaine, M., Devillez, A., Moufki, A. and Dudzinski, D. Mode-lling of cutting forces in ball-end milling with tool–surface inclination Part II. Influence of cutting conditions, run-out, ploughing and inclination angle, Journal of Materials Processing Technology, 2007, Vol. 189, pp 85-96. [Dow 2004] Dow, A., Miller, L. and Garrard, K. Tool force and deflection com-pensation for small milling tools, Precision Engineering, 2004, Vol. 28, pp 31-45. [Raju 2011] Raju, K., Janardhan, G., Kumar, P. and Rao, V., Optimization of cutting conditions for surface roughness in CNC end milling, International journal of precision engineering and manufacturing, 2011, Vol. 12, No. 3, pp 383-391. [Aramcharoen 2008] Aramcharoen, A., Mativvenga, P. T., Yang, S., Cooke, K. E., and Teer, D. G. “Evaluation and selection of hard coating for micro milling of hardened tool steel, ” International Journal of Machine Tools and Manufacture, 2008, Vol. 48, pp. 1578–1584.


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HSM2014–14033

INVESTIGATION ON MICROMILLING OFEBM TI6AL4V TITANIUM ALLOY

Z. Rysava1, G. Tristo1*, S. Bruschi1

1UNIVERSITY OF PADUA, DEPARTMENT OF INDUSTRIAL ENGINEERING, PADUA, ITALY


ABSTRACTAdditive manufacturing is a promising technology that can be employed for the fabrication of micro-components made of difficult-to-cut metals, such as Titanium and Cobalt alloys. Additive manufacturing not only reduces the wastes of material, which is typical of subtractive manufacturing, but also enables the fabrication of micro-components characterized by gradients in their chemical composition and density. However, the surface quality and dimensional accuracy of the parts produced by additive manufacturing processes are often not compatible with the requirements of the most demanding applications. A possible solution is offered by the combination of the advantages of additive manufacturing with the precision and accuracy, as well as the high surface quality, achievable by micromachining, where the former is used to produce a semi-finished product that is then finished

[Afazov 2013] Afazov, S. M., et al. Effects of micro-milling conditions on the cutting forces and process stability. J. Mater. Process. Technol., May 2013, Vol. 213, No. 5, pp. 671–684. [Aramcharoen 2009] Aramcharoen, A. and Mativenga, P. T. Size effect and tool geometry in micromilling of tool steel. Precis. Eng., October 2009, Vol. 33, No. 4, pp. 402–407. [ARCAM 2014] ARCAM. Ti6Al4V Titanium alloy. Catalogue. [on line] Available at <http://www. arcam.com/technology/products/metal-powders/catalogue> (consulted 05/05/2014). [Dornfeld 2006] Dornfeld, D., et al. Recent advances in mechanical microma-chining. CIRP Ann. Technol., January 2006, Vol. 55, No. 2, pp. 745–768. [Dhanorker 2007] Dhanorker, A., et al. Micromilling Process Planning and Modeling for Micromold Manufacturing. ASME 2007 Int. Manuf. Sci. Eng. Conf., 2007, pp. 759–769. [Fachcini 2010] Fachcini, L. Microstructure and mechanical properties of bio-medical alloys produced by Rapid Manufacturing techniques. Thesis. Italy: Univeristy of Trento, January 2010. [Filiz 2007] Filiz, S., et al. An experimental investigation of micro-machinability of copper 101 using tungsten carbide micro-endmills. Int. J. Mach. Tools Manuf., June 2007, Vol. 47, No. 7–8, pp. 1088–1100. [Harrysson 2008] Harrysson, O. L., et al. Direct metal fabrication of titanium implants with tailored materials and mechanical properties using electron beam melting technology. Mater. Sci. Eng. C, Aprile 2008, Vol. 28, No. 3, pp. 366–373. [Jahanmir 2011] Jahanmir, S. Surface Integrity in Ultrahigh Speed Microma-chining. Procedia Eng., January 2011, Vol. 19, pp. 156–161. [Liu 2006] Liu, X., et al. An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining. J. Manuf. Sci. Eng., 2006, Vol. 128, No. 2, pp. 474

Micromachining; titanium alloy; machinability; surface topography; burrsKEYWORDS

REFERENCES

by the latter. This paper deals with the micro-machinability of Ti6Al4V Titanium alloy parts fabricated by means of Electron Beam Melting (EBM) additive manufacturing process and devoted to the biomedical sector. A number of cutting experiments are conducted on an ultra-precise micro-milling machine by varying the most relevant process parameters, such as the cutting speed and feed rate. The experiments are carried out under dry cutting conditions by using uncoated tungsten carbide micro-end mills having a diameter of 0. 3 mm. The surface roughness and topography of the milled surfaces are investigated as a function of the cutting parameters, as well as the surface integrity in terms of micro-hardness and microstructural alterations in comparison with the as-delivered Ti6Al4V EBM. The chip morphology and the burrs characteristics are also analyzed.

[Milan 2010] Mian, J. A., et al. A comparative study of material phase effects on micro-machinability of multiphase materials. Int. J. Adv. Manuf. Technol., January 2010, Vol. 50, No. 1–4, pp. 163–174[Murr 2009a] Murr, L. E., et al. Microstructure and mechanical behavior of Ti-6Al-4V produced by rapid-layer manufacturing, for biomedical applications. J. Mech. Behav. Biomed. Mater., January 2009, Vol. 2, No. 1, pp. 20–32. [Murr 2009b] Murr, L. E., et al. Microstructures and mechanical properties of electron beam-rapid manufactured Ti–6Al–4V biomedical prototypes compa-red to wrought Ti–6Al–4V. Mater. Charact., February 2009, Vol. 60, No. 2, pp. 96–105. [Özel 2007] Özel, T., et al. Modelling and simulation of micro-milling process. New Jersey, U. S. A.: Rutgers University, Piscataway, Dept. of Industrial & Sys-tems Engineering, Manufacturing Automation and Research Laboratory, 2007. [Özel 2011] Özel, T., et al. Experiments and finite element simulations on micro-milling of Ti–6Al–4V alloy with uncoated and cBN coated micro-tools. CIRP Ann. – Manuf. Technol., January 2011, Vol. 60, No. 1, pp. 85–88. [Parthasarathy 2010] Parthasarathy, J., et al. Mechanical evaluation of porous titanium (Ti6Al4V) structures with electron beam melting (EBM). J. Mech. Behav. Biomed. Mater., Aprile 2010, Vol. 3, No. 3, pp. 249–59. [Thepsonthi 2012] Thepsonthi, T., et al. Multi-objective process optimization for micro-end milling of Ti-6Al-4V titanium alloy. Int. J. Adv. Manuf. Technol., March 2012, Vol. 63, No. 9–12, pp. 903–914. [Thepsonthi 2013] Thepsonthi, T. and Özel, T. Experimental and finite element simulation based investigations on micro-milling Ti-6Al-4V titanium alloy: Effects of cBN coating on tool wear. J. Mater. Process. Technol., Aprile 2013, Vol. 213, No. 4, pp. 532–542. [Yan 2013] Yan, Y., et al. Effect of density and pore morphology on fatigue pr-operties of sintered Ti–6Al–4V. Int. J. Fatigue, October 2013, Vol. 55, pp. 81–91.


HSM2014–14045

STUDY OF ELEMENTARYMICRO-CUTTING IN HARDENED TOOL STEEL

R. Piquard1*, A. Gilbin1, M. Fontaine1, A. D’Acunto2, S. Thibaud1, D. Dudzinski2

1FEMTO-ST UMR 6174, CNRS/UFC/ENSMM/UTBM, DÉPTMÉCANIQUE APPL., BESANÇON, FRANCE2LEM3 UMR 7239, UNIVERSITÉ DE LORRAINE, ARTS ET MÉTIERS PARISTECH, CNRS, ENIM, METZ, FRANCE


ABSTRACTThis paper deals with micromachining and in particular with the study of micro-cutting in the context of metals micro-milling. Micro-milling is basically characterized by tools with a diameter less than 1 mm and that can reach 0. 05 mm. These tools have no longer complex and sharp geometries as conventional tools because of manufacturing difficulties. With such small tools, cutting parameters are also very different from conventional machining, and manufacturers usually advise "adapted" cutting conditions such as feed per tooth smaller than 10 μm. However, an approach based on scale reduction (top-down) leads in micro-milling to the emergence of critical size effects. These size effects are the main issues in understanding the mechanisms of micro-cutting. Most of the published studies focus on experiments and force models directly applied to the case of micro-milling, and, at this scale, it is very complicated to identify and separate dynamical, geometrical and cutting problems from cutting forces and surfaces observation A solution to clarify the analyses and to propose a proper modelling approach is to consider a simpler case, namely the elementary micro-cutting where the assumption of a rigid and straight tool is more suitable. Then experimental data obtained in

[Afazov 2010] Afazov, S. M., Ratchev, S. M. and Segal, J., Modelling and simulati-on of micro-milling cutting forces. Journal of Materials Processing Technology. 2010. Vol. 210, n° 15, pp. 2154-2162. DOI 10. 1016/ j. jmatprotec. 2010. 07. 033. [Altintas 2011] Altintas, Y. andJin, X., Mechanics of micro-milling with round edge tools. CIRP Annals-Manufacturing Technology. 2011. Vol. 60, n° 1, pp. 77–80. [Bissacco 2008] Bissacco, G., Hansen, H. N. andSlunsky, J., Modelling the cutting edge radius size effect for force prediction in micro milling. CIRP Annals – Manufacturing Technology. 2008. Vol. 57, n° 1, pp. 113-116. DOI 10. 1016/j. cirp. 2008. 03. 085. [Fleisher 2009] Fleisher, J., Schulze, V. andKotshenreuter, J., Extension of

Micro-cutting; micro-milling; experimentation; simulation; hardened tool steelKEYWORDS

REFERENCES

elementary micro-cutting configurations can be used to develop an adapted model which can be applied in a second phase to the case of the micro-milling and finally extended with dynamical issues. In this view, orthogonal and oblique micro-cutting tests were conducted directly on a milling machine for uncut chip thicknesses from 0. 165 to 12 microns and two different cutting angles. The tests were carried out on 40NiCrMo16 steel thin tubes and with a cutting speed of 60 m/min. The results have clearly shown the influence of the cutting edge radius on the measured forces and the existence of different zones: for the lower uncut chip thicknesses, ploughing is dominant with intermittent chip formation, whereas for larger values of thickness, chip formation was continuous and the cutting phenomenon appeared more important than ploughing. Specific cutting forces are calculated and their evolution is in a good agreement with ones identified from previous micro-milling tests. To complete the study, phenomenological as well as thermo-mechanical models are in development. The purpose is to define a relevant elementary micro-cutting model and to apply it to the micro-milling process by summing elementary forces along the discretized cutting edge.

cutting force formulae for microcutting. CIRP Journal of Manufacturing Science and Technology. 2009. Vol. 2, n° 1, pp. 75–80. [Fontaine 2007] Fontaine, M., Devillez, A. and Dudzinski, D., Parametric geo-metry for modelling of milling operations. International Journal of Machining and Machinability of Materials. 2007. Vol. 2, n° 2, pp. 186–205. [Gilbin 2012] Gilbin, A., Influence of feed rate in micro-milling studied from experiments and micro-cutting laws identification. Proceedings of the 8th International Conference on MicroManufacturing. 2013. [Merchant 1945] Merchant, ME, Mechanics of the metal cutting process. American Institute of Physics. 1945. [Richard 1999] Richard, F., http://mic2m. univ-fcomte. fr/, 1999


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HSM2014–14051

STUDY OF BURR FORMATION AND PHASE TRANSFORMATION DURING MICRO-MILLING OF NITI ALLOYS

R. Piquard1, A. D’Acunto1, D. Dudzinski1*

1LEM3 UMR CNRS 7239, 4, RUE AUGUSTIN FRESNEL, 57070 METZ, FRANCE


ABSTRACTMicro-milling can be defined as milling with end mills smaller than 1 mm of diameter. The top-down approach from milling to micro-milling is often used to define cutting conditions. Unfortunately geometries either for the active part or the overall shape are quite different from conventional tools, leading to inexistent problems at the macro-scale, such as a larger cutting edge radius to uncut chip thickness ratio leading to ploughing effect. Moreover, micro-milling can be used on particular material such as Shape Memory Alloys in biomedical domain which are difficult to machining. This study focuses on burr formation during shoulder milling for two biocompatible NiTi alloys: a martensitic NiTi (shape memory effect) and an austenitic one (pseudo-elasticity effect). Design of experiment is used to highlight the influence of various parameters

[Aurich 2009] Aurich, J. C., Dornfeld, D., Arrazola, P. J., Franke, V., Leitz, L. and Min, S., Burrs—Analysis, control and removal. CIRP Annals – Manufacturing Technology. 2009. Vol. 58, n° 2, pp. 519-542. DOI 10. 1016/j. cirp. 2009. 09. 004. [Gillespie 1999] Gillespie, L. K., Deburring and edge finishing handbook. 1999. SME. ISBN 0872635015. [Hashimura 1995] Hashimura, M., Ueda, K., Dornfeld, D., and Manabe, K. Ana-lysis of three-dimensional burr formation in oblique cutting. CIRP Annals-Manu-facturing Technology, 1995, Vol. 44(1), pp. 27-30. [Lekkala 2011] Lekkala, R., Bajpai, V., Singh, R. K. and Joshi, S. S. Characte-rization and modeling of burr formation in micro-end milling. Precision Engi-neering-Journal of the International Societies for Precision Engineering and Nanotechnology. 2011. Vol. 35, n° 4, pp. 625-637. DOI 10. 1016/j. precisioneng. 2011. 04. 007. WOS: 000294239500009. [Olvera 1996] Olvera, O. and Barrow, G. An experimental study of burr formation in square shoulder face milling. International Journal of Machine Tools and Manufacture. 1996. Vol. 36, n° 9, pp. 1005–1020.

Burr formation; micro-milling; nickel-titanium alloys; design of experimentsKEYWORDS

REFERENCES

(cutting parameters and material phases) on the burr formation in micro-milling NiTi alloys. Burrs were observed and measured using confocal, optical and electronic microscopy and tend to be as large as shoulders dimensions. Material phase transformation was also examined. Analysis of Variance emphasizes that the larger the feed per tooth and the smaller the width of cut are, the smaller the top burr is. Cutting strategy leads to different burr shape: in up-milling burrs have a large curvature, whereas in down-milling burrs are slightly bent. An affected layer of about 10 μm has been observed for the austenitic NiTi. The proposed experimental approach gave the opportunity to study burr formation in micro-milling and the machinability of alloys or superelastic NiTi shape memory and a qualitative explanation of burr formation has been developed.

[Weinert 2004a] Weinert, K., Petzoldt, V. and Kötter, D. Turning and drilling of NiTi shape memory alloys. CIRP Annals-Manufacturing Technology. 2004. Vol. 53, n° 1, pp. 65–68. [Weinert 2004b] Weinert, K. and Petzoldt, V. Machining of NiTi based shape memory alloys. Materials Science and Engineering: A. 2004. Vol. 378, n° 1, pp. 180–184. [Weinert 2008] Weinert, K. and Petzoldt, V. Machining NiTi micro-parts by micro-milling. Materials Science and Engineering: A. 2008. Vol. 481, pp. 672–675. [Wu 1999] Wu, S. K, Lin, H. C et Chen, C. C. A study on the machinability of a Ti49. 6Ni50. 4 shape memory alloy. Materials Letters. 1999. Vol. 40, n° 1, pp. 27-32. DOI 10. 1016/S0167-577X(99)00044-0.


HSM2014–14039

2D TOOL-PATH GENERATION METHOD FOR MULTI-AXIS MILLING MACHINE USING TOF CAMERA

R. Ahmad1, 2*, P. Plapper1, 1FSTC-RUES, UNIVERSITY OF LUXEMBOURG, LUXEMBOURG2MECHANICAL ENGINEERING DEPARTMENT, CECOS UNIVERSITY, PAKISTAN

*Corresponding author; e-mail: [email protected]; [email protected]

ABSTRACTMulti-axis machines are known for their precise production of complex parts, where multi-tool are working in the same area or static workpiece support or clampingparts, may cause collision problems. It is therefore necessary to identify potential collision risks and avoid them in an efficient way, which may cause production stops and machinery damage. This research study has been focusing on safe non-functional (rapid) tool-path generation for multi-axis milling machine, where no efficient automatic collision avoidance solution exists (in the literature). A 3D Time of Flight (TOF) camera attached into the machine will be able to sense any unwanted situation in the manufacturing environment and provide

[Ahmad 2012] Ahmad, R., Tichadou, S., Hascoet, J. Y., 2012, 3D Safe and intelli-gent trajectory generation for multi-axis machine tools using machine vision, International Journal of Computer-Integrated manufacturing, [Ahmad 2011] Ahmad, R., Tichadou, S., Hascoet, J. Y., 2011. New computer vision based Snakes and Ladders algorithm for the safe trajectory of two axis CNC machines. Journal of Computer Aided Design, Doi: 10. 1016/j. cad. 2011. 12. 008. [Ahmad 2010] Ahmad, R., Tichadou, S., Hascoet, J. Y., 2010. Integration of vision based image processing for multi-axis CNC machine tool safe and efficient trajectory generation and collision avoidance. Journal of Machine Engineering 10 (4), 53-65. [Ata 2006] Ata, A., Myo, T., 2006. Collision-free trajectory planning for manipu-lators using generalized pattern search. International Journal of Simulation and Modelling 5 (4), 145–154. [Bohez 2003] Bohez, Minh, Kiatsrithanakorn, Natasukon, Ruei-Yun, and Son] Bohez, E. L. J., Minh, N. T. H., Kiatsrithanakorn, B., Natasukon, P., Ruei-Yun, H., Son, L. T., 2003. The stencil buffer sweep plane algorithm for 5-axis CNC tool path verification. Computer-Aided Design 35 (12), 1129 – 1142. [Garcia 2012] Garcia Becerro F., 2012, “Sensor fusion combining 3-D and 2-D for depth data enhancement, ” PhD Thesis, University of Luxembourg. [Hascoet 1993] Hascoet, J. Y., Bennis, F., Guerin, F., 1993. Optimization of tool tra-jectory for five axis control machining. Int. Conf. Iasted Robotics and Manufactu-ring, Oxford, England, 23-25 September 1993, Pp 120–122, ISBN 0 88986 179 X [Heidelberger 2004] Heidelberger, B., Teschner, M., and Gross, M., 2004. Detection of collisions and self-collisions using image-space techniques. Journal of WSCG, 12(3), 145–152. [Ho 2001] Ho, S., Sarma, S., Adachi, Y., 2001. Real-time interference analysis between a tool and an environment. Computer-Aided Design 33 (13), 935 – 947. [Jun 2003] Jun, C. -S., Cha, K., Lee, Y. -S., 2003. Optimizing tool orientations for 5-axis machining by configuration-space search method. Computer-Aided Design 35 (6), 549 – 566. [Lee 1997] Lee, S., Kardaras, G., July 1997. Elastic string based global path planning using neural networks. In Computational Intelligence in Robotics and Automation, CIRA’97, Proceedings. IEEE International Symposium on, 108 –114.

Safe tool-path generation; collision detection and avoidance; 3D TOF camera; multi-axis machinesKEYWORDS

REFERENCES

rapid and automatic solution to detect and avoid collisions for safe tool movements during production. In the presence of obstacles, the proposed approach will provide decisions regarding tool-path correction and improvement automatically. The proposed algorithm based on 3D vision concept is also able to take into account unknown obstacle shape, size during production but dynamic aspects of the scene will be treated in future. The concept presented take into account the 3D information from the scene for traversal safe tool-paths generation for a static environment as an initial application, which will be adapted to more complex real machining scenarios by integrating it with STEP-NC technology in future.

[Makhanov 2007a] Makhanov, S., 2007a. Optimization and correction of the tool path of the five-axis milling machine: Part 1. Spatial optimization. Mathematics and Computers in Simulation, 75(5 – 6), 210 – 230. Applied Scientific Compu-ting: Advanced Grid Generation, Approximation and Simulation. [Makhanov 2007b] Makhanov, S., 2007b. Optimization and correction of the tool path of the five-axis milling machine: Part 2: Rotations and setup. Mathema-tics and Computers in Simulation, 75(5- 6): 231 – 250. Applied Scientific Com-puting: Advanced Grid Generation, Approximation and Simulation. [Moravec 1985] Moravec, H., and Elfes, A., 1985. High resolution maps from wide angle sonar. In Robotics and Automation Proceedings. 1985 IEEE Inter-national Conference, 2, 116 – 121. [Morishige 1997] Morishige, Kase, and Takeuchi] Morishige, K., Kase, K., Take-uchi, Y., 1997. Collision-free tool path generation using 2-dimensional C-space for 5-axis control machining. The International Journal of Advanced Manufacturing Technology (13), 393 – 400. [Moriwaki 2008] Moriwaki, T., 2008. Multi-functional machine tool. CIRP Annals – Manufacturing Technology 57 (2), 736 – 749. [Petiot 1998] Petiot, J. F., Chedmail, P., and Hascoet, J. Y., 1998. Contribution to the scheduling of trajectories in robotics. Robotics and Computer-Integrated Manufacturing, 14, 237 – 251. [Rauch 2012] Rauch, M., Laguionie, R., Hascoet, J. Y., and Suh, S. H., 2012. An advanced STEP-NC controller for intelligent machining processes. Robotics and Computer-Integrated Manufacturing, 28, 375 – 384. [Sasiadek 2000] Sasiadek, J. Z., Duleba, I., Oct. 2000. “3D Local Trajectory Planner for UAV”, Journal of Intelligent and Robotic Systems, Vol. 29, 191-210. [Tang 2007] Tang, T., Bohez, E. L., Koomsap, P., 2007. The sweep plane algori-thm for global collision detection with workpiece geometry update for five-axis NC machining. Computer-Aided Design 39 (11), 1012 – 1024. [Tang 2014] Tang, T., 2014. Algorithms for collision detection and avoidance for five-axis NC machining: A state of the art review. Computer-Aided Design 51, 1–17. [Wang 2006] Wang, Q. H., Li, J. -R., Zhou, R. -R., 2006. Graphics assisted app-roach to rapid collision detection for multi-axis machining. The International Journal of Advanced Manufacturing Technology 30, 853 – 863.


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HSM2014–14041

PARAMETERS SET-UP FOR COLLISION AVOIDANCE AND SMOOTH MOTIONIN 5-AXIS END MILLING BASED ON A POTENTIAL FIELD APPROACH

V. Lacharnay1, C. Tournier1*, S. Lavernhe1

1ÉCOLE NORMALE SUPÉRIEURE DE CACHAN, LURPA, CACHAN, FRANCE


ABSTRACTDespite the evolution of CAM software, 5-axis tool path programming requiresadvanced skills and global collision detection remains a challenge during the tool pathcomputation. In the literature, the problem of collision avoidance is mainly treated as aniterative process based on local and global collision tests with a geometrical methodwhereas in the field of robotics, other methods based on potential fields virtually attached tothe obstacle are developed. Thus, we have developed an innovative approach to show thebenefit of using potential fields in order to prevent collisions during the computation of thetool axis orientation in 5-axis milling. In the proposed approach, the tool is considered as a rigid body moving in 3D spaceon which repulsive and attractive forces are acting. Repulsive forces are due to potentialfields attached to check surfaces and an attractive force exerted by a spring and a viscousdamper is introduced to restore the tool axis orientation in the programmed configuration. The tool center follows the programmed path on the part surface whereas the tool axisorientation is modified to avoid the obstacle by resolving the fundamental principle ofdynamics. Our main goal is the definition of a smooth behavior of the tool axis orientation alongthe

[Choi et al. 1997] Choi, B. K., Kim, D. H. and Jerard, R. B. C-Space approach to tool-path generation for die and mould machining. Computer-Aided Design 1997; 29(9): 657-669. [Monies et al. 2004] Monies, F., Mousseigne, M., Redonnet, J. M. and Rubio, W. Determining a collision-free domain for the tool in five-axis machining. International Journal of Production Research 2004, 42(21): 4513-4530. [Morishige et al. 1997] Morishige, K., Kase, K. and Takeuchi, Y. Collision--Free Tool Path Generation Using 2-Dimensional C-Space for 5-Axis Control Machining. International Journal of Advanced Manufacturing Technology 1997; 13: 393- 400. [Lee et al. 1995] Lee, Y-S. and Chang, T-C. 2-Phase approach to global tool interference avoidance in 5-axis machining. Computer-Aided Design 1995; 27(10): 715-729. [Balasubramaniam et al. 2000] Balasubramaniam, M., Laxmiprasad, P., Sarma, S. and Shaikh, Z. Generating 5-axis NC roughing paths direct-

5-axis machining; collision-free; potential field; tool path generation; ball-end millingKEYWORDS

REFERENCES

path in order to maximize the tool feedrate on the machine tool. As the tool behaves likea damped harmonic oscillator, investigations are carried out to prevent the tool axisorientation from oscillating. In particular, the effects of simulation parameters such as inertia, spring stiffness, damping parameter and obstacle neighborhood distance are investigated. Usually, parts encountered in 5-axis milling exhibit continuous check surfaces modeledas parametric surfaces. In order to apply the proposed approach, the check surfaces have tobe tessellated and each point of the mesh is considered as a repulsive point. Thus severalpossibilities exist to compute the total repulsive force acting on the tool and three differentsolutions are compared to ensure a smooth tool axis motion. Numerical investigations arecarried out on “open pocket” parts such as turbines blades. Research works developed in this paper allow to ensure the robustness of an originalmethod for 5-axis collision avoidance using potential fields commonly used in robotics. Potential fields allows to be sure that no collision will ever occur with the obstacles as theyemit a repulsive force growing to infinity when the tool gets closer to the obstacle.

ly from a tesselated representation. Computer-Aided Design 2000; 32(4): 261-277. [Ho et al. 2003] Ho, M-C., Hwang, H-R. and Hu, C-H. Five-axis tool orien-tation smoothing using quaternion interpolation algorithm. International Journal of Machine Tools & Manufacture 2003; 43: 1259–1267. [Bi et al. 2010] Bi, Q. Z., Wang, Y. H., Zhu, L. M. and Ding, H. Generating collision-free tool orientations for 5-axis nc machining with a short ball--end cutter. International Journal of Production Research 2010; 48(24): 7337-7356. [Khatib 1986] Khatib, O. Real-Time Obstacle Avoidance for Manipulators and Mobile Robots. The International Journal of Robotics Research 1986; 5(1): 90- 98. [Koren et al. 1991] Koren, Y. and Borenstein, J. Potential field methods and their inherent limitations for mobile robot navigation. IEEE Transactions on robotics and automation 1991; 1398–1404.


HSM2014–14042

FEEDRATE OPTIMIZATION IN 5-AXIS MACHINING BASED ON DIRECT TRAJECTORY INTERPOLATION ON THE SURFACE USING AN OPEN CNC

X. Beudaert1, S. Lavernhe1*, C. Tournier1

1LURPA, ENS CACHAN, UNIVERSITÉ PARIS SUD, CACHAN, FRANCE


ABSTRACTFree-form surfaces are used for many industrial applications from aeronautical parts, to molds or biomedical implants. In the common machining process, CAM software generates approximated tool paths based on tolerances such as chordal deviation because of the limitation induced by the input tool path format of the industrial CNC. Indeed, only linear interpolation, which produces tangency discontinuities, and native or real time polynomial interpolation are proposed. Then, during the tool path interpolation, marks on finished surfaces can appear induced by non-smooth feedrate planning. Managing the geometry of the tool path as well as the kinematical parameters of the machine tool are two key factorsfor quality and productivity improvements. The aim of this paper is to present a unified method to compute the trajectory directly on the surface to be machined avoiding CAM approximations and producing a smoother trajectory. The Direct Trajectory Interpolation on the Surface (DTIS) method allows to obtain both a higher productivity and a better surface quality. The novelty of the proposed approach relies on the interpolation of the trajectory based on the free form surface mathematical model while considering the kinematical limitations of a high-speed milling machine (velocity, acceleration

[Beudaert 2012] Beudaert, X., Lavernhe, S., Tournier, C., Feedrate interpo-lation with axis jerk constraints on 5-axis NURBS and G1 tool path. Interna-tional Journal of Machine Tools and Manufacture, 2012, Vol. 57, pp 73-82. [Beudaert 2013] Beudaert, X., Lavernhe, S., Tournier, C., 5-axis local corner rounding of linear tool path discontinuities. International Journal of Machi-ne Tools and Manufacture, 2013, Vol. 73, pp 9–16. [Cheng 2006] Cheng C. -W., Tseng W. -P., Design and implementation of a real-time NURBS surface interpolator. The International Journal of Advan-ced Manufacturing Technology, 2006, Vol. 30, pp 98–104. [Chen 2014] Chen, Z. C., Khan, M. A., A new approach to generating arc length parameterized NURBS tool paths for efficient three-axis machi-ning of smooth, accurate sculptured surfaces. The International Journal of Advanced Manufacturing Technology, 2014, Vol. 70, pp 1355–1368. [Erkorkmaz 2006] Erkorkmaz, K., Yeung, C. -H., Altintas, Y., Virtual CNC system. Part II. High speed contouring application. International Journal of Machine Tools and Manufacture, 2006, Vol. 46, No. 10, pp 1124–1138. [ISO14649–10] ISO14649–10 Industrial automation systems and integration – Physical device control – Data model for computerized numerical controllers – Part 10: General process data, 2004. [ISO14649–11] ISO14649–11 Industrial automation systems and integration – Physical device control – Data model for computerized numerical controllers – Part 11: Process data for milling, 2004. [Koren 1995] Koren, Y., Lin, R. -S., Five-Axis Surface Interpolators. CIRP Annals – Manufacturing Technology, 1995, Vol. 44, No. 1, pp 379-382. [Langeron 2004] Langeron, J-M., Duc, E., Lartigue, C., Bourdet, P., A new format for 5-axis tool-path computation, using B-spline curves. Computer--Aider Design, 2004, Vol. 36, No. 12, pp 1219–1229. [Lartigue 2001] Lartigue, C., Thiebaut, F., Maekawa, T., CNC tool path in terms of B-spline curves. Computer-Aided Design, 2001, Vol. 33, No. 4, pp 307-319.

5-axis machining; open CNC; surface interpolation; maximum feedrate; jerkKEYWORDS

REFERENCES

and jerk). Furthermore, experimental investigations are carried out with an Open CNC on a 5-axis high speed milling machine in order to show the benefits of the proposed method compare to the classical strategies available with an industrial CNC, especially the Siemens Sinumerik 840D. Fair comparisons are proposed to demonstrate the benefits of the DTIS approach over the classical approaches in terms of maximum reachable feedrate and machining time. An aluminum test part is machined in 5-axis with a bull nose cutter with 5 different strategies. The first two strategies use the most popular format, which is the linear interpolation (G1)with two different CAM tolerances, 10 μmand 1 μmrespectively. Two other strategies use the native B-Spline format generated with Catia V5 CAM software and interpreted directly by the Siemens 840D CNC with the previous tolerances. The last strategy uses the DTIS algorithm, which performs both tool positioning and feedrate interpolation in a synchronous manner with the PREMIUM OpenCNC. Results show that the machining time is reduced by more than twice compared to the best industrial solution, i. e. the native B-Spline interpolation and by more than four times compared to the commonly used G1 format.

[Lartigue 2004] Lartigue, C., Tournier, C., Ritou, M., Dumur, D., High-Per-formance NC for HSM by means of Polynomial Trajectories. CIRP Annals – Manufacturing Technology, 2004, Vol. 53, No. 1, pp 317-320. [Liang 2013] Liang, H., Li, X., Five-axis STEP-NC controller for machining of surfaces. The International Journal of Advanced Manufacturing Techno-logy, 2013, Vol. 68, No. 9–12, pp 2791-2800. [Lin 2000] Lin, R. -S., Real-time surface interpolator for 3D parametric sur-face machining on 3-axis machine tools. International Journal of Machine Tools and Manufacture, 2000, Vol. 40, No. 10, pp 1513–1526. [Omirou 2005] Omirou, S. L., Barouni, A. K. Integration of new program-ming capabilities into a CNC milling system. Robotics and Computer-Inte-grated Manufacturing, 2005, Vol. 21, No. 6, pp 518-527. [Otsuki 2004] Otsuki, T., Ogino, H., Ide, S., Chiba, T., Curve interpolati-on method, Japan, Fanuc LTD. Yamanashi (US Patent 6823234 B2), 2004. [Pateloup 2010] Pateloup, V., Duc, E., Ray P., Bspline approximation of circle arc and straight line for pocket machining. Computer-Aided Design, 2010, Vol. 42, No. 9, pp 817-827. [Rauch 2012] Rauch, M., Laguionie, R., Hascoet, J-Y., Suh, S-H., Advanced STEP-NC controller for intelligent machining processes. Robotics and Computer-Integrated Manufacturing, 2012, Vol. 28, No. 3, pp 375-384. [Siemens 2009] Siemens, Sinumerik – 5 axis machining, DocOrderNo. 6FC5095-0AB10-0BP1, 2009. [Tsai 2003] Tsai, M. C., Cheng, C. W., Cheng, M. Y. A real-time NURBS surface interpolator for precision three-axis CNC machining. International Journal of Machine Tools and Manufacture, 2003, Vol. 43, No. 12, pp 1217–1227. [Yutkowitz 2005] Yutkowitz, S. J., Chester, W., Apparatus and method for smooth cornering in a motion control system, United States, Sie-mens Energy & Automation, Inc. Alpharetta, GA (US Patent 6922606), 2005.


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HSM2014–14085

A NEW ALGORITHM FOR SMOOTH AND EFFICIENT MORPHING-BASED PLANAR TOOL PATH GENERATION

Y. Wang1, Ch. Yan1, 2, Ch. H. Lee1*, J. Yang1, J. Shi1

1NATIONAL NC SYSTEM ENG. RESEARCH CENTER, HUAZHONG UNIV. OF SCIENCE &TECHNOLOGY, WUHAN, CHINA2MANUFACTURING INTELLIGENCE ENG. RESEARCH CENTER, WUHAN INSTITUTE OF TECHNOLOGY, WUHAN, CHINA


ABSTRACTThis paper aims to provide a two dimensional tool path generation algorithm applicable to blade machining, two dimensional pocket milling with or without islands, and planar face milling. In order to produce a smoother and continuous tool path without intermediate lifts, we present a new path generating approach based on a scalar field that is determined by the Laplace's equation. The offset contours are determined by the iso-potential lines of the field, and a spiral tool path is constructed by morphing

[Bieterman 2003] Bieterman, M. B. and Sandstrom, D. R. A curvilinear tool--path method for pocket machining, International Mechanical Engineering Congress and Exposition, New Orleans, Louisiana, USA, November 17–22, 2002, 125, (4), pp. 709-715[Choiet al. 1998] Choi, B. K. and Jerard, R. B. Sculptured Surface Machining, Kluwer Academic Publishers, 1998. [Chuang 2007] Chuang, J. J. and Yang, D. C. H. A laplace-based spiral con-touring method for general pocket machining, The International Journal of Advanced Manufacturing Technology, 2007, 34, (7), pp. 714-723[Fenkl 2002] Fenkl, H., et al. Milling method. ALSTOM(Switzerland)Ltd, 2002. [Held 2009] Held, M. and Spielberger, C. A smooth spiral tool path for high spe-ed machining of 2D pockets, Computer-Aided Design, 2009, 41, (7), pp. 539-550[Lee 2003] Lee, E. Contour offset approach to spiral toolpath generation with constant scallop height, Computer-Aided Design, 2003, 35, (6), pp. 511-518[Makhanov 2003] Makhanov, S. S. and Ivanenko, S. A. Grid generation as applied to optimize cutting operations of the five-axis milling machine, Applied Numerical Mathematics, 2003, 46, (3), pp. 331-351[Osher 1988] Osher, S. and Sethian, J. A. Fronts propagating with curvatu-re-dependent speed: algorithms based on Hamilton-Jacobi formulations, Journal of Computational Physics, 1988, 79, (1), pp. 12-49

Tool path generation; scalar field; laplace'sequation; gradient curve; spiral tool pathKEYWORDS

REFERENCES

between consecutive contour lines. A geometry approachis used to avoid the spiral’s self-intersection. In some cases, the distance between inner and outer boundaries of the machining region is highly uneven; the generated tool path will have uneven step-over distributions. To avoid this drawback we further provide a hybrid method combining zig and spiral patterns. Experiments show that the new approach improves the machining efficiency and reduces the tool path length.

[Roy 2008] Roy, R., et al. Programming of a machining procedure for adaptive spiral cutting trajectories, ACMOS'08 Proceedings of the 10th WSEAS Inter-national Conference on Automatic Control, Wisconsin, USA, 2008 [Hauth 2011] Hauth, S. and Linsen, L. Double-spiral tool path in configurati-on space, The International Journal of Advanced Manufacturing Technology, 2011, 54, (9–12), pp. 1011–1022[Sethian 1996] Sethian, J. A. A fast marching level set method for monotoni-cally advancing fronts, Proceedings of the National Academy of Sciences of the United States of America, 1996, 93, (4), pp. 1591–1595[SmartCAM 2014] SmartCAM V18 Core Milling Improvements. (see http://www.smartcamcnc.com/Products/Release/V18/smartcam_v18_morph_pa-ttern_toolpath_and_other_milling_improvements.php)[TopSolid 2011] TopSolid'Newsletter #55, 2011. (see http://www.topsolid.com/data/newsletter/international/2011/topsolidnewsletter-55.htm )[Xiong2011] Xiong, Z. H., et al. Curvilinear tool path generation for pocket machining, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2011, 225, (4), pp. 483[Zhou 2013] Zhou, B., et al. Generation method for five-axis NC spiral tool path based on parametric surface mapping, Journal of Systems Science and Complexity, 2013, 26(5): 676-694


HSM2014–14016

WEAR STUDY AND PERFORMANCE EVALUATION IN THE MACHINING OF MMC WITH PCD AND PCBN TOOLS

M. I. Sadik1*

1SANDVIKCOROMANT AB, R&D MATERIALS AND PROCESSES, 126 80 STOCKHOLM, SWEDEN


ABSTRACTThe paper attempts to study the ability of the polycrystalline diamond (PCD) and polycrystalline boron nitride (PCBN) in dry milling of aluminium-silicon carbide (Al-SiC) metal matrix composite (MMC) using different grades. Al-SiC composite containing 20% wt of Sic was used as workpiece material. Two different PCD grades and two PCBN grades were used at various cutting speed and feed while the depth of cut was constant. Furthermore the effects of cutting data on the tool life at high cutting speed (1000-7000 m/min) and

[Avinash 2007] Avinash, C., Raguraman, S., Ramaswamy, S., Muthukrishnan, N. An investigation on effect of workpiece reinforcement percentage on tool wear in cutting Al-SiC metal matrix composites. ASME international me-chanical engineering congress and exposition 2007 November 11–15; Seattle, Washington, USA-IMECE2007-41231. [Bhattacharyya 1992] Bhattacharyya, D., Bowis, M. E., Gregory, J. T. The in-fluence of microsphere reinforcement on the mechanical behaviour and weldability of a 6061 aluminium metal matrix composite. ASM IntSymp. Machining of Composite Materials; Chicago; 1992 pp. 49-56. [Couper 1991] Couper, M. J., Xia, K. Development of microsphere reinfor-ced metal matrix composites. Int. Symp. Material Science, Denmark 1991; pp. 291-298.

PCD; PCBN; MMC; abrasive wearKEYWORDS

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usual productive cutting speed (400-700 m/min) was investigated. The results showed that tool life was totally dominated by two wear mechanisms flank wear and edge fracture which are mainly influenced by the characteristically properties of the grade like the content of main phase (Diamond/CBN). The wear studies were conducted using SEM to reveal basic mechanisms behind different wear. The wear analysis indicates that three bodies friction is a basic mechanism which determinate the tool life.

[Salomon 1931] Salomon, C. 1931; German Patent: 523594. [Heath 2001] Heath, Peter J. Developments in applications of PCD tooling, Journal of Material Processing Technology 2001; 116: 31-38. [Lin1995] Lin, J. T., Bhattacharyya, D., Lane, C. Machinability of a silicon carbide reinforced aluminium metal matrix composite. Wear 1995; 181–183: 883-888. [Muthukrishnan 2008] Muthukrishnan, N., Murugan, M., Prahlada, Rao K. Machinability issues in turning of Al-Sic (10p) metal matrix composites. Int. J Adv. ManufTechnol 2008; 39: 211-218. [Manna 2003] Manna, A., Bhattacharyya, B. A study on machinability of Al-SiC MMC. J Mater Process Technol 2003, 1; 40: 711-716. [Shaw 1984] Shaw, M. C. Metal cutting principles, Clarendon, Oxford Series on advanced manufacturing 3; 1984.


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HSM2014–14017

COMPARISON OF MACHINING INCONEL 718 WITH CONVENTIONAL AND SUSTAINABLE COOLANT

D. Fernández1*, V. García Navas1, A. Sandá1, I. Bengoetxea1

1IK4-TEKNIKER. ADVANCED MANUFACTURING TECHNOLOGIES. EIBAR, SPAIN


ABSTRACTThe use of super-alloys, most of them Ni- or Ti-based, has significantly increased during the last decade. Industries such as the aerospace, energy or transport, use these kinds of materials due to their excellent properties that combine hardness, high temperature strength and thermal shock and corrosion resistance. These desirable material properties make these alloys extremely difficult to machine, since high values of temperature and shear forces are easily achieved and a quick cutting tool wear turns out to be an important process constraint. Thus, with the objective to overcome this phenomenon, several methods can be used; the most common one is to add large amounts of water-based or oil-based cutting fluids directly into

[Krain 2007] Krain, H., Sharman, A. and Ridgway, K. “Optimisation of tool life and productivity when end milling Inconel 718TM”. Journal of Materials Proce-ssing Technology, 2007, 189: 153-61.[Dudzinski 2004] Dudzinski, D. “A review of developments towards dry and high speed machining of Inconel 718 alloy”. International Journal of Machine Tools and Manufacture, 2004, 44: 439-56. [Leshock 2001] Leshock, C. E. and Kim J. N. “Plasma enhanced machining of Inconel 718: modeling of workpiece temperature with plasma heating and ex-perimental results”. International Journal of Machine Tools and Manufacture, 2001, 41: 877-97. [Hong 2000] Hong, A. Y. and Broomer, M. “Economical and ecological cryoge-nic machining of AISI 304 austenitic stainless steel”. Clean Products and Pro-cesses, 2000, 2: 157–166. [Dhar 2006] Dhar, N. R., Islam, S., Kamruzzaman, Md. and Paul, S. “Wear Be-havior of Uncoated Carbide Inserts under Dry, Wet and Cryogenic Cooling Con-ditions in Turning C-60 Steel”. Journal of the Braz. Soc. of Mech. Sci. & Eng., April-June, 2006, Vol. XXVIII, No. 2. [Bicek 2012] Bicek, M., Dumont, F., Courbon, C., Pusavec, F., Rech, J. and Ko-pac, J. “Cryogenic machining as an alternative turning process of normalized and hardened AISI 52100 bearing steel”. Journal of Materials Processing Tech-nology, 2012, 212: 2609– 2618. [Ahmed 2007] Ahmed, M. I., Ismail, A. F., Abrakr, Y. A., Nurul Amin, A. K. M. “Effectiveness of cryogenic machining with modified tool holder”. Journal of Materials Processing Technology, 2007, 185: 91–96. [Hong 2001] Hong, S., Ding, Y. “Cooling approaches and cutting temperatures in cryogenicmachining of Ti-6Al-4V” International Journal of Machine Tools & Manufacture 41 (2001) 1417–1437. [Berminghan 2011] Berminghan, M. J., Kirsch, J., Sun, S., Palanisamy, S., Dar-gusch, M. S. “New observations on tool life, cutting forces and chip morpholo-gy in cryogenic machining Ti-6Al-4V”. International Journal of Machine Tools & Manufacture, 2011, 51: 500–511. [Berminghan 2012] Berminghan, M. J., Palanisamy, S., Kent, D., Dargusch, M. S. “A comparison of cryogenic and high pressure emulsion cooling technolo-gies on tool life and chip morphology in Ti–6Al–4V cutting”. Journal of Materi-als Processing Technology, 2012, 212: 752– 765. [Pusavec 2010] Pusavec, F., Kramar, D., Krajnik, P., Kopac J. “Transitioning to sustainable production – part II: evaluation of sustainable machining technolo-gies”. Journal of Cleaner Production, 2010, 1–11.

Cryogenic; machining; inconel; turningKEYWORDS

REFERENCES

the cutting zone. However, nowadays other less conventional fluids are also being studied with the aim of achieving a more ecological and efficient process in the machining of these difficult-to-cut materials. Examples of this are vortex cold air or cryogenic cooling, among others. In this study a comparison between different cooling methods in turning of Inconel 718 is presented, which is the most commonly used nickel based alloy in the industry. Tool life and workpiece surface finish has been analyzed in each case, searching the pros and cons of each cooling technique. The results reveal the possibility of replacing traditional pollutant cooling fluids by other more ecologically friendly alternatives.

[Wang 2000] Wang, Z. Y. and Rajurkar, K. P. “Cryogenic machining of hard-to--cut materials”. Wear, 2000, 239: 168–175. [Wang 2003] Wang, Z. Y., Rajurkar, K. P., Fan, J., Lei, S., Shin, Y. C. and Petrescu, G. “Hybrid machining of Inconel 718”. International Journal of Machine Tools & Manufacture, 2003, 43: 1391–1396. [Ravi 2011] Ravi, S. and Kumar, M. P. “Experimental investigations on cryoge-nic cooling by liquid nitrogen in the end milling of hardened steel”. Cryogenics, 2011, 51: 509–515.[Truesdale 2009] Truesdale, S. L., Shin, Y. C. “Microestructural analysis and machinability improvement of udimet 720 via cryogenic milling”. Machining Science and Technology (2009) 13: 1–19[Nalbant 2011] Nalbant, M. and Yildiz, Y. “Effect of cryogenic cooling in milling process of AISI 304 stainless steel”. Trans. Nonferrous Met. Soc. China, 2011, 21: 72-79.[Shokrani 2012] Shokrani, A., Dhokia, V., Newman, S. T. and Imani-Asrai, R. “An Initial Study of the Effect of Using Liquid Nitrogen Coolant on the Surface Roughness of Inconel 718 Nickel-Based Alloy in CNC Milling”. Procedia CIRP, 2012, 3: 121 – 125.[Ko 1999] Ko, T. J., Kim, H. S. and Chung B. G. “Ail-oil cooling method for turning of hardened material”. International Journal of advanced Manufacturing Technology 1999, 15: 470–477. [Boswell 2009] Boswell B. and Chandratilleke T. T. “Air-Cooling Used For Metal Cutting”. Am. J. Appl. Sci., 1999, 6(2): 251-262. [Liu 1997] Liu, C. and Hu, R. “Cooling air from vortex tube applied to cutting tool cooling”. Manufacturing Technology & Machine Tool, 1997, 1: 30–31. [Liu 2007] Liu, J., Chou, K. “On temperatures and tool wear in machining hype-reutectic Al–Si alloys with vortex-tube cooling”. International Journal of Machi-ne Tools & Manufacture 47 (2007) 635–645.[Kim 2001] Kim, S. W., Lee, D. W., Kang, M. C. and Kim, J. S. “Evaluation of machinability by cutting environments in high-speed milling of difficult-to-cut materials”, Journal of Materials Processing Technology, 2001, 111, 256–260. [Rahman 2003] Rahman, M., Senthil Kumar, A., Manzoor-Ul-Salam, and Ling, M. S. “Effect of chilled air on machining performance in end milling” Internati-onal Journal of Advanced Manufacturing Technology, 2003, 21: 787–795. [Yamazaki 2003] Yamazaki, T., Miki, K. and Sato, U. “Cooling air cutting of Ti-6Al-4V alloy”, Journal of Japan Institute of Light Metals, 2003, 53 (10), 416–420. The complete list of literature is available on the enclosed CD.


HSM2014–14073

CHARACTERIZATION OF THE CUTTING PHENOMENON IN ORBITAL DRILLING OF TITANIUM ALLOYS (TIAL6V4)

P. A . Rey1*, K . Moussaoui1, J. Senatore1, Y. Landon1

1INSTITUT CLÉMENT ADER (ICA) UNIVERSITÉ DE TOULOUSE ; INSA, UPS, MINES ALBI, ISAE BÂT 3R1, 118 ROUTE DE NARBONNE, F-31062 TOULOUSE CEDEX 9, FRANCE


ABSTRACTThe orbital drilling, also called helical milling, is a process notably used in the aeronautical industry. It is very different from the axial drilling. It consists in machining a hole with a tool which has a smaller diameter, driven on a helical trajectory. This process is used especially because it generates low cutting forces. As a consequence, the burr formation at the entry and at the exit of the hole is largely reduced, so as the risk of delamination when drilling CFRP. Operations such as cleaning or deburring are then considerably reduced. The orbital drilling is a complex operation. Due to the tool trajectory, chip thickness is highly variable along the cutting edges at each tool rotation position. This is why cutting forces are very difficult to estimate. The aim of this study is to determinate the influence of tool geometry and cutting conditions

[Brinksmeier et al. 2008] Brinksmeier, B; Sascha Fangmann.; Meyer, I; "Helical milling of CFRP-Titanium layer compounds"; In: Prod. Eng. Res. Devel, pp. 2: 277–283; Germany 2008[Denkena et al. 2008] Denkena, B., Boehnke, D., Dege, J. H. "Helical milling of CFRP-Titanium layer compounds"; In: CIRP Journal of Manufacturing Science and Technology, pp. 64-69; Germany 2008[Fontaine 2004] Fontaine, M. "Modélisation thermomécanique du fraisage de forme et validation expérimentale" Thesis at Metz University ; France ; 2004[Lorong et al. 2008] Lorong, P., Ali, "Logiciel explicite en thermomécanique pour la simulation et la formation d’un copeau en usinage"; In: Mécanique et industrie, pp. 343-349; Vol3 ; 2002

Orbital drilling; TiAl6V4; tool geometry; cutting forcesKEYWORDS

REFERENCES

on cutting forces and on the final quality of the machined holes. At first, the geometry of the chip is modeled taking into account the parameters defining the trajectory and the tool. A cutting force model, based on the instantaneous chip thickness, is then set up. An experimental study validates the cutting force model through measurements of cutting forces during orbital drilling tests, for varying cutting parameters and tool geometries. Dimensional measurements are also realized on drilled holes using a three-dimensional measuring machine. Using cutting force model and the results of tests, it is possible to conclude on the influence of cutting parameters and tool geometry on the hole geometric quality. Then, the optimization of these parameters in order to increase the final quality of the hole is proposed.

[Lutze 2008] Lutze, S. State of the art and expectations for the future of orbital drilling. Thesis at Leuphana University Lüneburg School III 2008[Merchant 1945] Merchant, M. E. Mechanics of the metal cutting process, I. Orthogonal cutting, In : Journal of Applied physics, vol 16 p318-324. 1945[Oxley 1989] Oxley, P. L. B. Mechanics of metal cutting, Ellis horwood, Chichester, UK, 1989[Segonds et al 2006] Segonds, S., Landon, Y., Monies, F., Lagarrigue, P. Method for rapid characterisation of cutting forces in end milling considering runout, in: International Journal of Machining and Machinability of Materials, vol. 1 (1), pp. 45-61, 2006.


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HSM2014–14074

STUDY OF TANGENTIAL FORCE EXERTED ON RAKE FACE DURING HIGH-SPEED END MILLING OF INCONEL 718

M. S. Kasim1, C. H. Che Haron2*, J. A. Ghani2, A. H. Musfirah2, M. N. A. Rahman1, M. A. Ali1, M. S. A. Aziz1

1FACULTY OF MANUFACTURING ENGINEERING, UNIVERSITITEKNIKAL MALAYSIA MELAKA, HANG TUAH JAYA, MELAKA, MALAYSIA 2DEPARTMENT OF MECHANICAL AND MATERIAL ENGINEERING, FACULTY OF ENGINEERING AND BUILT ENVIRONMENT, UNIVERSITIKEBANGSAAN MALAYSIA, BANGI, SELANGOR, MALAYSIA


ABSTRACTMost of the problems arise during end milling of Inconel 718 due to notch wear and flaking. These problems located near depth of cut line caused by repetitive cyclic load. This study presents an experimental investigation on the effect of various cutting parameters in high-speed machining of aged Inconel 718 on the tangential force. The effect of cutting speed, feed rate, depth of cut and width of cut on cutting forces had been studied. The cutting parameters were cutting speed, Vc of 100–140 m/min, feed rate, fz of 0. 1-0. 2 mm/tooth, depth of cut, ap of

[Alauddin 1996] Alauddin, M., et al. Modelling of cutting force in end milling Inconel 718. Journal of Materials Processing Technology, 1996, Vol. 58, No. 1., pp 100–108. [Alauddin 1998] Alauddin, M., et al. Cutting forces in the end milling of Inconel 718. Journal of Materials Processing Technology, 1998, Vol. 77, No. 1., pp 153–159. [Altintas 1996] Altintas, Y. and Lee, P. 1996. A general mechanics and dynamics model for helical end mills. CIRP Annals – Manufacturing Technology, 1996, Vol. 45, No. 1., pp 59-64. [Aspinwall 2007] Aspinwall, D. K., et al. 2007. The influence of cutter orien-tation and workpiece angle on machinability when high-speed milling Inconel 718 under finishing conditions. International Journal of Machine Tools and Manufacture, 2007, Vol. 47, No. 12–13., pp 1839–1846. [Dudzinski 2004] Dudzinski, D., et al. A review of developments towards dry and high speed machining of Inconel 718 alloy. International Journal of Machine Tools and Manufacture, 2004 Vol. 44, No. 4., pp 439-456. [Grzesik 2008] Grzesik, W. Advanced Machining Processed of Metallic Materials; Theory, Modelling and Applications 1st Ed., Oxford, 2008. [Izamshah 2012] Izamshah, R., et al. Hybrid deflection prediction on machi-ning thin-wall monolithic aerospace components. Journal of Engineering Manufacture, 2012, Vol. 226, No. 4., pp 13. [Kamata 2007] Kamata, Y., and Obikawa, T. High speed MQL finish-turning of Inconel 718 with different coated tools, Journal of Material Processing Technology, 2007, Vol. 192, pp 281-286.

Inconel 718; high-speed milling; tangential forces; minimum quantity lubrication; end millKEYWORDS

REFERENCES

0. 5–1. 0 mm and width of cut, ae of 0. 2–1. 8 mm. Force were measure using a Kistler model 5070 A dynamometer with the output force in X, Y, Z axis. The model was proposed by considering rake angle to calculate exact value tangential force exerted onto rake surface. The result shows that the width of cut is the main factors in controlling tangential force during end milling, followed by depth of cut and feed rate. These factors controlling volume material removed so that larger stress created on the cutter rake face.

[Kasim 2013] Kasim, M. S., et al. Wear mechanism and notch wear location prediction model in ball nose end milling of Inconel 718. Wear, 2013, Vol. 302, No. 1–2., pp 1171–1179. [Krain 2007] Krain, H. R., et al. Optimisation of tool life and productivity when end milling Inconel 718TM. Journal of Materials Processing Techno-logy, 2007, Vol. 189, No. 1-3., pp 153–161. [Kurt 2009] Kurt, A. Modelling of the cutting tool stresses in machining of Inconel 718 using artificial neural networks. Expert Systems with Applica-tions, 2009, Vol. 36, No. 6., pp 9645-9657. [Li 2006] Li, H. Z., et al. An experimental study of tool wear and cutting force variation in the end milling of Inconel 718 with coated carbide inserts. Jour-nal of Materials Processing Technology, 2006, Vol. 180, No. 1-3., pp 296-304. [Lin 2006] Lin, S. Y., et al. Life prediction system using a tool’s geometric shape for high-speed milling. The International Journal of Advanced Ma-nufacturing Technology, 2006, Vol. 30, No. 7-8., pp 622-630. [Sharif 2007] Sharif, S. and Rahim, E. A. Performance of coated- and unco-ated-carbide tools when drilling titanium alloy-Ti-6Al4V. Journal of Materi-als Processing Technology, 2007, Vol. 185, No. 1-3., pp 72-76. [Zhuang 2014] Zhuang, K., et al. Notch wear prediction model in turning of Inconel 718 with ceramic tools considering the influence of work hardened layer. Wear, 2014, Vol. 313, No. 1–2., pp 63-74.


HSM2014–14038

DYNAMIC MODELLING OF AN ELECTRO–HYDRAULIC ACTUATOR TO ISOLATE MACHINE TOOLS FROM GROUND VIBRATIONS

M. Wabner1*, M. Law1, S. Ihlenfeldt1

1FRAUNHOFER INSTITUTE FOR MACHINE TOOLS AND FORMING TECHNOLOGY IWU, CHEMNITZ, GERMANY


ABSTRACTMachine tools installed on non-rigid structures are subjected to high vibration levels emanating from vibration producing machines and devices such as from metal forming machines, unbalanced rotors, reciprocating mechanisms, etc. Isolating the machine from such disturbances is critical for assuring their adequate performance, especially in situations where the amplitude of external vibrations significantly exceeds the magnitude of allowable machining/measurement deviations. The goal of vibration isolation hence is to reduce the intensity of dynamic excitations transmitted to the machine such that relative vibration amplitudes in the work zone are kept below permissible levels. In most cases, the isolation requirements can be satisfied by properly selected passive isolators that have high damping and relatively small support stiffness. However, since the nature of the external disturbance may include forced, steady state and random vibrations with varying amplitudes, it becomes difficult to design and implement effective passive isolation solutions, and active solutions are often necessary. To meet these objectives, a novel electro-hydraulic actuator has been developed at the Fraunhofer IWU, and this paper thus concerns itself with the dynamic modeling of this electro-hydraulic system to demonstrate how

[Abicht 2002] Abicht, C., Ulbrich, H. and Riebe, S., Active vibration isolati-on of a stewart-platform using high response hydraulic actuators, Proce-edings of the 6th Int. Conference on Motion and Vibration Control, 2002. [Bischoff 2009] Bischoff, Martin, Entwicklung eines aktiven Aufstellele-mentes zur Schwingungsisolierung von Werkzeugmaschinen, Masterarbeit, Hochschule für Technik, Wirtschaft und Kultur Leipzig, 2009 (in German). [Bishop 2002] The Mechatronics Handbook (Editor-in-Chief: Robert Bishop), CRC Press, 2002, 602-607. [Choi 2005] Choi, Y. T., Wereley, N. M. and Jeon, Y. S. Semi-Active Vibration Isolation Using Magnetorheological Isolators, Journal of Aircraft, 2005, 42, 1244–1251. [DeBra 1992] DeBra, D. B. Vibration Isolation of Precision Machine Tools and Instruments, Annals of the CIRP, 1992, 41, 2, 711-718. [Huang 2003] Huang, X., Elliott, S. J., Brennan, M. J. Active isolation of a flexible

Machine tools; active vibration isolation; electro-hydraulic actuatorKEYWORDS

REFERENCES

ground vibrations may be efficiently isolated. At first, position control of the electro-hydraulic system is formulated. Following this, for a lumped model of a machine, machine response to ground motion is discussed. Ground motion is then included as a disturbance to the electro-hydraulic actuator. The ground motion results in machine motion, which is countered by an opposing motion from the actuator which results in the ground motion being isolated. Device performance is investigated for representative levels of floor vibrations experienced by machine tools. Controlled closed-loop transmissibility shows the actuator to have excellent attenuation of ground vibrations for excitation frequencies of up to 30 Hz. Simulation based investigations suggest that the ground vibrations may indeed be isolated to a large extent, with isolations up to 80% for the cases investigated. Experimental validation is necessary to test the fidelity of the models and forms part of the planned future work. Because of their high passive stiffness, in the absence of external disturbances, the active machine mounts can also be used in the passive condition. Since the device can be used on demand, i. e. only when high disturbances are observed or when high precision is required, it offers an energy efficient and economical solution.

structure from base vibration, Journal of Sound and Vibration, 2003, 263, 357–376. [Meritt 1967] Merritt, H. E. Hydraulic Control Systems, Wiley, 1967. [Moog 1965] Transfer Functions for Moog Servovalves, Technical Bulliten, Moog Controls Inc., 1965. [Parker2011] Direct Operated Proportional DC Valve, Series D3FP, Technical Catalogue, Parker, 2011. [Rivin 1995] Rivin, Eugene, Vibration isolation of precision equipment, Preci-sion Engineering, 1995, 17, 41-56. [Rydberg 2008] Rydberg, Karl-Erik, Hydraulic servo systems – Lecture Notes, IEI/ Fluid and Mechanical Engineering Systems, Linköpings Universitet, 2008. [Wabner 2012] Wabner, M., Ihlenfeldt, S. Aufstellelement, Patent No. DE102012010196 (A1), 2012 (in German).


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HSM2014–14040

DAMPING IN LINEAR GUIDESCONSIDERING OPERATIONAL FACTORS

C. Brecher1, M. Fey1, M. Wagner1*

1LABORATORY OF MACHINE TOOLS AND PRODUCTION ENGINEERING WZL, RWTH AACHEN UNIVERSITY, GERMANY


ABSTRACTThe high demand for performance and accuracy of machine tools requires a specific design of the dynamic machine behavior. By optimizing virtual prototypes during development phase, time and cost savings can be realized. The calculation of frequency response functions enables the prediction of the dynamic behavior for machine tools. Inertia and stiffness of structural components can be calculated using material parameters and geometric data. For common machine elements, corresponding information is provided by the manufacturer. Eigen modes and eigen frequencies can be well predicted using FE simulations. However, critical eigen modes cannot be identified, due to unprecise information about amplitude and phase. For a complete simulation of the dynamic behavior, the system damping has to be known. The system damping cannot be determined with sufficient accuracy due to the lack of knowledge about the local damping properties of joints and machine components.Within the DFG-funded project "Methodology for the measurement of damping effects in machine tools" an extended parameter identification method has been developed. This extended method enables the determination of local damping parameters by separating the damping of the machine component from the damping of the test bench. As a result damping parameters

[Altintas 2004] Altintas, Y. and Weck, M. Virtual Machine Tools, CIRP Annals – Manufacturing Technology (2004), Volume 53, Issue 2, pp 619–642[Brecher 2013] Brecher, C., Fey, M., Bäumler, S. Damping models for machine tool components of linear axes. CIRP Annals – Manufacturing Technology (2013), Volume 62, Issue 1, pp. 399-402[Brecher 2012] Brecher, C., Fey, M., Bäumler, S. Identification method for damping parameters of roller linear guides. Production Engineering (2012), Volume 6, Issue 4-5, pp. 505-512

Machine tool; damping; linear guideKEYWORDS

REFERENCES

determined by this method are valid for different dynamic systems. The damping behavior of machine components depends on various influences. As a consequence further investigations are necessary. In previous research, design-related factors on the damping behavior of linear guides have been studied, e.g. the preload class, size and type of rolling elements. The research presented in this paper focuses on operational factors like different loads in their amount and direction, the influence of lubricant’s viscosity and movement. The research on the influence of operational conditions offers a deeper knowledge about damping effects and is required in order to obtain damping parameters, which could be used to improve the prediction accuracy of the dynamic behavior for machine tool structures in operation by simulation models. It is shown that the damping of important mode shapes increases significantly with viscosity of the applied lubrikant and for an exemplarily linear axis was detected that movement also has a significant impact on the damping behavior of linear guides. Furthermore, the calculation and measurement of a real machine structure shows exemplarily that damping ratios can be predicted well using damping parameters, which are identified using the extended methodology.

[Großmann 2008] Großmann, K., Rudolph, H. Dämpfungs beschreibung für die modellgestützte dynamische Strukturanalyse. ZWF 103 (2008), Volume 11, pp. 767-773[Kunc 2013] Kunc. Identifikation und Modellierung von nicht linearen Dämpfungs effekten in Vorschubachsen für Werkzeugmaschinen. Aachen: Apprimus Verlag, 2013. ISBN: 9783863591205


HSM2014–14036

A NEW DEVICE FORSPINDLE ACCURACY INSPECTION

G. H. J. Florussen1*, M. A. A. Morel1, H. A. M. Spaan1

1IBS PRECISION ENGINEERING, EINDHOVEN, THE NETHERLANDS


ABSTRACTSpindles are one of the most important machine components. The quality of a spindle is usually measured by combining a Master-ball or Master-cylinder with 3 or 5 capacitance sensors mounted in a sensor nest. A disadvantage of this method is that it requires a clean environment because oil, water and cooling liquid affect the dielectric constant (i. e. ε) and therefore disturb/destroy the measurement results. IBS Precision Engineering is developing the Spindle Inspector as a quick health check of the machine’s spindle performance and is typically applied in between machining operations. Instead of using capacitance sensors, eddy current sensors are used as these are robust for

[Baas 2011] Baas, M. The development of a next generation measurement probe for the purpose of machine tool calibration. Report ME11. 009. Delft: Delft University of Technology, Precision and Microsystems Engineering 2011. [ISO 2006] ISO 230-7: 2006 Test code for machine tools – Part 7: Geometric accuracy of axis of rotation. ISO 2006.

Machine tool; metrology; spindles; error motion; axis shiftsKEYWORDS

REFERENCES

dirt and liquids. A complicating factor however, the electrical run-out effect, should be taken into account as the target is rotating. In this paper the development of this Spindle Inspector is described together with an analysis of the obtained measurement results for validation. Next to radial and axial error motions, also axis shifts are studied in detail displacing the rotor relative to the spindle’s stator (which alters the bearing’s contact angle) if the spindle speed is changed. The Spindle Inspector is intended as an industrial solution to rapidly check spindle performance between 250 and 40k RPM. Measurement time is limited to a few minutes only and measurements are executed fully automatic.

[Marsh 2010] Marsh, E. R. Precision Spindle Metrology, second edition. Lancas-ter, Pennsylvania: DEStech Publications Inc, 2010. ISBN 978–1-60595-003-7.


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HSM2014–14082

STUDY ON VIBRATION RESPONSE OF HIGH-SPEED SPINDLE WITH BEARING DEFECTS

H. Cao1*, Y. Li1, X. Zhang1, X. Chen1

1STATE KEY LABORATORY FOR MANUFACTURING SYSTEMS ENGINEERING, XI’AN JIAOTONG UNIVERSITY, XI’AN 710049, PR CHINA


ABSTRACTRolling bearing plays a significant role in high-speed spindle system, which affects both the static and dynamic properties of system considerably. Meanwhile, it is usually the weakest part in a spindle as surface defects often occur on inner raceway, outer raceway, or balls. Bearing defect is one of the most common root causes of vibration and noise in high-speed spindles. In this paper, a finite element (FE) model of high-speed spindle with localized defects of bearing is proposed. The drawbar, shaft and housing and other beam structures are modeled as Timoshenko’s beam, while sleeve, and other disk components are modeled as disk element. Finally, all the components’ model are integrated together to establish the FE model of the high-speed spindle system and the Newmark βmethod is used to solve the vibration response of spindle system numerically. The FE model of the spindle-bearing system was verified by conducting dynamic tests

[Lin 2003] Lin, C. W., Tu, J. F. and Kammman, J. An integrated thermo-me-chanical-dynamic modelto characterize motorized machine tool spindles during very high speed rotation. Int. J. Mach. Tool Manu., 2003, Vol. 2, No. 10., pp 1035–1104. [Cao 2004] Cao, Y. and Altintas, Y. A general method for the modeling of spindle-bearing system. ASME J. Mech Design, 2004, Vol. 126, No. 6., pp 1089–1104. [Cao 2010] Cao, H., Holkup, T. and Altintas, Y. A comparative study on the dyna-mics of high speed spindles with respect to different preload mechanisms. Int J. Adv. Manuf. Technol., 2010, Vol. 57, pp 871-883. [Cao 2012] Cao, H., Niu, L. and He, Z. Method for vibration response simulation and sensor placement optimization of a machine tool spindle system with a bearing defect. Sensors, 2012, Vol. 12, No. 7., pp 8732-8754. [Gagnol 2007] Gagno, V., Bougarrou, B. C. and Ray, P., et al. Stability-based spindle design optimization. ASME J. Manuf. Sci. Eng., 2007, Vol. 129, No. 2., pp 407-415. [Li 2009] Li, H. and Shin, Y. C., Integration of thermo-dynamic spindle and machining simulation models for a digital machining system. Int. J. Adv. Manuf. Technol., 2009, Vol. 40, No. 7-8., pp 648-661.

Spindle; rolling bearing; dynamic modeling; localized defect; vibration responseKEYWORDS

REFERENCES

on an experimental spindle, good agreements of experiment and simulation show the accuracy of proposed model. Based on the Jones’ bearing theory, a defective bearing model for outer raceway defect, inner raceway defect, or ball defect, is proposed by adding additional deflection into the distance between ball center and raceway groove center when the ball rolls over the defect. The established defect model is integrated into the FE model of spindle. Then the vibration responses of spindle system with different kinds of defect bearing (including outer raceway defect, inner raceway defect, ball defect and multiple defect) under varied operating conditions (with cutting loads or no loads) are simulated, and their vibration characteristics are analyzed and discussed in both time domain and frequency domain, which may provide useful proofs for condition monitoring and fault diagnosis of high-speed spindles.

[Sadok 2007] Sadok, S. and Bechir, B. A numerical model to predict damaged bearing vibrations. J. Vib. Control, October 2007, Vol. 13, pp 1603–1628. [Patel 2010] Patel, V. N., Tandon, N. and Pandey, R. K. A dynamic model for vibration studies of deep groove ball bearings considering single and multiple defects in races. ASME J. Tribol., 2010, Vol. 132, No. 4., pp 041101. [Nakhaeinejad 2011] Nakhaeinejad, M. and Bryant, M. D. Dynamic modeling of rolling element bearings with surface contact defects using bond graphs. ASME J. Tribol., 2011, Vol. 133, No. 1., pp 011102. [Niu 2014] Niu, L., Cao, H., He, Z., et al. Dynamic modeling and vibra-tion response simulation for high speed rolling ball bearings with localized defects in raceways. ASME J. Manuf. Sci. Eng. 2014, http://manufacturings-cience. asmedigitalcollection. asme. org/article. aspx?articleid=1857510, (Pu-blished online). [Cao 2012] Cao, H., Holkup, T., Chen, X. et al. Study on characteristic variations of high-speed spindles induced by centrifugalexpansion deformations. Journal of Vibroengineering, 2012, Vol. 14, No. 3., pp 1278–1291.


HSM2014–14018

VELOCITY MEASUREMENT OF CHIPS AT THE GUN DRILLING PROCESS WITH AN OPTICAL MEASUREMENT SYSTEM

F. Klocke1, G. Keitzel1*, D. Veselovac1

1RWTH AACHEN UNIVERSITY, LABORATORY FOR MACHINE TOOLS AND PRODUCTION ENGINEERING (WZL), AACHEN, GERMANY


ABSTRACTProcess monitoring and control are powerful tools to increase the performance of machining processes by operating closer to the physical limits without risking machine tool or work pieces defects. While the process monitoring of drilling processes using force and vibration signals has been extensively investigated, monitoring of chip breakage and chip transportation was disregarded up to now. Gun drilling is a high performance cutting process that is characterized by large aspect ratios and is commonly applied in the fields of automotive, aeronautic, power generation and medical devices. In contrast to conventional drilling processes, chip breaking and chip transport is – due to limited space in the drilling bead and the large aspect ratios – the limiting performance factor. In recent works it could be proved that chip velocities exceeded 16 m/s in a conventional gun drilling process employing tools with 2 mm in diameter. However, these chips are very small and difficult to detect in the widened beam of high pressure coolant.

[Baier 1985] Baier, J. Entwicklung einer digitalen AC-Grenzregelung für Tiefbohrmaschinen unter Betrachtung geeigneter Prozesskenngrößen. Dissertation, Universität Dortmund, 1985[Chin 1987] Chin, J. Voraussetzungen und Konzeption eines Grenzwertre-gelungs-Systems für das Einlippen-Tiefbohren. Dissertation, Universität Stuttgart, 1987[Klocke et al. 2012] Klocke, F., Gierlings, S., Adams, O., Auerbach, T., Kamps, S., Veselovac, D., Eckstein, M., Kirchheim, A., Blattner, M., Thiel, R., Kohler, D. New Concepts of Force Measurement Systems for Specific Machining Processes in Aeronautic Industry. In Proceedings of the 5th CIRP Conference on High Performance Cutting, Zurich, 4th-7th June, 2012, Procedia CIRP, Volume 1, 2012, p552-557

Innovative sensor concept; chip transportation; chip velocity; gun drillingKEYWORDS

REFERENCES

This paper presents the implementation and verification of velocity measurements using a novel integrated optical measurement system enabling chip monitoring for gun drilling processes. The sensor is integrated into the drilling bush holder as an extension of the drilling bush. This set up allows measurements when the beam of the chip-coolant-mixture is still focused. In a first step, the measurement principle is introduced and the sensor design providing velocity measurements on the basis of two different signal analysis methods. Subsequently, the measurement setup, test execution and the experimental results are presented. In order to verify the quality of the measurement system, high speed camera recordings were made in order to capture the chips coming out of the drilling bush. The distance-per-time analysis between single camera images delivers the actual velocity of the chips and allows for an assessment of the temporal resolution and reliability of the sensor.

[Klocke et al. 2014] Klocke, F., Keitzel, G., Veselovac, D. Innovative sensor concept for chip transport monitoring of gun drilling processes. In: 6thCIR-Pinternational conference onhigh performance cutting, procedia CIRP, Volume 14, 2014, pp. 460 – 465[Veselovac 2013] Veselovac, D. Process and Product Monitoring in the Drilling of Critical Aero Engine Components, Dissertation, RWTH Aachen University, 2013[Weinert et al 2000] Weinert, K., Löbbe, H., Webber, O. Spanüberwachung sichert den Prozess-Tiefbohren mit Einlippenbohrern. In: Heft 24, Technica, 2000, S. 16-21[Wirtz 2010] Wirtz, G. Adaptive Regelung für das Tiefbohren mit Einlippen-bohren kleiner Durchmesser. Dissertation, RWTH Aachen University, 2010


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HSM2014–14022

PHENOMENOLOGICAL INVESTIGATIONS OF HEAT SOURCES AND BOUNDARY CONDITIONS FOR METAL CUTTING PROCESSES

M. Brockmann1, Y. Frekers2, S. Gierlings1*, F. Klocke1, R. Kneer2, D. Veselovac1

1LABORATORY FOR MACHINE TOOLS AND PRODUCTION ENGINEERING, RWTH AACHEN, AACHEN, GERMANY2INSTITUTE OF HEAT AND MASS TRANSFER, RWTH AACHEN, AACHEN, GERMANY


ABSTRACTTemperature a key variable in metal cutting and has significant impact on tool wear mechanisms as well as tool life time. As a consequence, it is a direct cost factor concerning the manufacturing process. Moreover, the interaction of tool wear state and cutting temperature affect the quality of the machined feature. Excessive temperatures in the cutting zone usually lead to deteriorated surface and sub-surface properties. Quantitative measurements in metal cutting processes are difficult to obtain due to factors such as poor accessibility of the cutting zone, high cutting velocities and extreme temperature gradients. The conventional approach to the thermal characterization of metal cutting process includes calorimetric measurement procedures for determining the time-dependent cutting energy, as well as temperature measurements in discrete spots by means of thermocouples. Established analytical

[Abukhshim 2006] Abukhshim, N. A., Mativenga, P. T. and Sheikh, M. A. Heat generation and temperature prediction in metal cutting: A review and implications for high speed machining. International Journal of Machine Tools and Manufacture, Vol. 46, No. 7–8, pp 782-800. [Komanduri 2000] Komanduri, R. and Hou, Z. B. Thermal modeling of the

Temperature; heat sources; metalcutting; infrared thermography; boundaries; shear zone; contact zoneKEYWORDS

REFERENCES

models use these results in order to calculate the temperature distribution in the tool and the cutting zone. In principal, analytical approaches are independent from specific cutting conditions, however, are based on various assumptions regarding thermal boundary conditions, heat partition ratios and heat source positions. These assumptions are currently not validated by suitable measurements but affect the results computed on the basis of the model significantly. In the following article, microscopic high-speed infrared measurements being recorded during broaching the Nickel-based alloy Inconel 718 is analyzed. In a first step, phenomenological investigations are pursued in order to clarify thermal boundary conditions, i. e. adiabatic borders as well as positions and lengths of the primary and secondary heat sources. Furthermore, the heat partition ratios are investigated at the respective heat source and object interface locations.

metal cutting process. International Jour-nal of Mechanical Sciences, Vol. 42, No. 9, pp 1715–1752. [Dinc 2008] Dinc, C., Lazoglu, I. and Serpenguzel, A. Analysis of thermal fields in orthogonal machining with infrared imaging. Journal of Materials Processing Tech-nology, Vol. 198, No. 1–3, pp 147–154.


HSM2014–14046

PREDICTION AND COMPENSATION OF PROCESS INDUCED SHAPE DEVIATIONS IN MULTI-AXIS HIGH-SPEED HARD FINISH MILLING

M. Stolorz1*, M. Ottersbach2, R. Kalocsay2

1RTD CONSULTING UG(HAFTUNGSBESCHRÄNKT), HERZOGENRATH, GERMANY2FRAUNHOFER INSTITUTE FOR PRODUCTION TECHNOLOGYIPT, AACHEN, GERMANY


ABSTRACTRecent market studies in the field of turbo machinery predict a constant annual increase of around 5% of air traffic until 2035. This directly correlates with the steady growing need of high performance components for turbines and jet engines. These components are made of nickel and titanium based alloys, which have outstanding mechanical and high-temperature properties. These materials are known to be difficult to machine especially by multi-axis milling. The superimposed dynamical and thermal loadings on the milling tools and the complex geometry of the parts accompany with high costs for operational equipment and time consuming milling operations. An appropriate process and tool design is one key enabler for highly efficient manufacturing of complex work pieces. During the last years innovative geometrically adapted milling tools aim to combine geometrical flexibility of ball-end milling tools and high efficiency of bull-nose milling tools in one tool design. However milling of high performance materials with

Paper in a journal: [Biermann 2012] Biermann, D., Krebs, E., Scharow, A., Kersting, P. Using NC-path deformation for compensating tool deflections in micromilling of hardened steel. Procedia CIRP, 5th CIRP Conference on High Performance Cutting, 2012, 132–137[Cho 2002] Cho, M. W., Seo, T. I. Machining error compensation using radial basis function network based on CAD/CAM/CAI integration concept. Inter-national Journal of Production Research, 2002, 40 (9), 2159–2174[Kim 2002] Kim, G. M., Kim, B. H., Chu, C. N. Estimation of cutter deflection and form error in ball-end milling processes. International Journal of Machine Tools & Manufacture, 2002, 43, 917-924[Kline 1982] Kline, W. A., Devor, R. E., Shareef, I. A. The prediction of sur-face accuracy in end milling. Transaction of ASME, Journal Engineering for Industry, 1982, 104, 272-278[Rao 2006] Rao, V. S., Rao, P. V. M. Tool deflection compensation in periphe-ral milling of curved geometries. International Journal of Machine Tools & Manufacture, 2006, 46, 2036 – 2043[Rao 2012] Rao, P. V. M., Desai, K. A. On cutter deflection surface errors in peripheral milling International Journal of Material Processing Technology, 2012, 212, 2443 – 2454

Hard finish milling; shape deviations; prediction; compensation KEYWORDS

REFERENCES

geometrically adapted milling tools necessitates novel machining strategies, adapted process designs and novel CAM algorithms for tool path calculation. This publication presents actual results on process and strategy development in using a totally new milling tool design in finish milling of titanium alloys. The suggested tool design enables to increase the calculated tool path width locally while remaining the flexibility and geometrical precision of conventional ball-end milling tools in a global context. Increasing productivity significantly and generating better surface finish compared to existing tool designs make the novel geometrically adapted milling tools to a game changing factor in modern process chains for manufacturing of single blades and BLISKS. The potentials of the highly efficient milling strategies based on a novel milling tool design and an adapted process design are shown while finish milling of a geometrically complex single blade made of TiAl6V4.

Technical reports or thesis: [OECD 2012] OECD: How manufacturing can create value and jobs, OECD Observer No 292, Q3 2012[OECD 2011] OECD: Attractiveness for Innovation: Location Factorsfor International Investment, OECD, ISBN: 9789264104815 (PDF); DOI: 10. 1787/978926410-4815-en, Q2 2011[Radzevich 2008] Radzevich, S. P. Kinematic geometry of surface machi-ning. CRC Press Taylor & Francis Group, BocaRaton 2008 (in English)[Urban 2009] Urban, A. Kinematische und mechanische Wirkungen des Kugelkopffräsens. Berichte aus dem IFW, doctorthesis, Hanover Universi-ty, IFW, Hanover 2009 (in German)[Will 2008] Will, J. C. Adaptronische Spindeleinheit zur Abdrängungs- und Schwingungskompensa-tion in Fräsprozessen. Berichte aus dem IFW, doctorthesis, Hanover University, IFW, Hanover2008 (in German)


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HSM2014–14014

CNC DATA ACQUISITION:SYSTEM DEVELOPMENT AND VALIDATION

E. G. Del Conte1*, K. Schützer2, A. A. Andrade1, R. T. Coelho3, A. J. Abackerli4

1CECS, CENTER FOR ENGINEERING, MODELING AND APPLIED SOCIAL SCIENCES, FEDERAL UNIVERSITY OF ABC, SÃO BERNARDO DO CAMPO, BRAZIL2SCPM, LAB. FOR COMPUTER INTEGRATED DESIGN AND MANUFACTURING, METHODIST UNIVERSITY OF PIRACICABA, SANTA BÁRBARA D'OESTE, BRAZIL3EESC, DEPARTMENT OF PRODUCTION ENGINEERING, UNIVERSITY OF SÃO PAULO, SÃO CARLOS, BRAZIL4IPT, CENTER FOR BIONANO MANUFACTURING, INSTITUTE FOR TECHNOLOGICAL RESEARCH, SÃO PAULO, BRAZIL


ABSTRACTThe Open architecture controller is a well known concept to promote the implementation of intelligent machine performance functions on shop floor. However there are no further investigations about the system validation, considering the data acquisition on interpolator level. This study aims at the development of a CNC data acquisition system considering the implementation of a procedure

[Kume 1993] Kume, Hitoshi. Métodos estatísticos para melhoria da qualidade. Gente, 1993. [Oliveira 2008] Oliveira, J. F. G., et al. "Architecture for machining process and production monitoring based in open computer numerical control. " Procee-dings of the Institution of Mechanical Engineers, Part B: Journal of Enginee-ring Manufacture 222. 12 (2008): 1605–1612. [Pritschow 2001] Pritschow, Günter, et al. "Open controller architecture–past, present and future. " CIRP Annals-Manufacturing Technology 50. 2 (2001): 463-470. [Schützer 2012] Schützer, K., et al. "Improvement of surface accuracy and

Open CNC; data acquisition; system validationKEYWORDS

REFERENCES

to validate the data transfer. Continuous monitoring of open CNC variables was implemented and experiments for system validation were performed on milling machining centers. The results of the implemented data transfer validation procedure show the system feasibility to continuously acquire the CNC data.

shop floor feed rate smoothing through open CNC monitoring system and cutting simulation. " Procedia CIRP 1 (2012): 90-95. [Siemens 1997] Siemens AG, OEM package MMC Release 4 System installation. 1997. [Teti 2010] Teti, Roberto, et al. "Advanced monitoring of machining operations. " CIRP Annals-Manufacturing Technology 59. 2 (2010): 717-739. [Yun 2007] Yun, W., Min, B. and Pasek, Z. J. "Open Architecture Controller Interface Implementation for Machine Tools. " IPROMS 2007 Innovative Produc-tion Machines and Systems (2007).


HSM2014–14024

INTEGRATION OF DISCONTINUOUS MILLING OPERATIONS INTO THE FLOW PRODUCTION OF SHEET METAL PROFILES

S. Schmidt1*, E. Abele1

1INSTITUTE OF PRODUCTION MANAGEMENT, TECHNOLOGY AND MACHINE TOOLS (PTW), TECHNISCHEUNIVERSITÄT DARMSTADT, GERMANY


ABSTRACTBifurcated structures such as plants or bones are very essential for a lot of applications in design of automobiles, machines, buildings etc. Typical examples for bifurcated structures are multi-chambered profiles which are used as elements of lightweight construction in various fields of engineering. The demand for increase in productivity and the use of potential lightweight construction is the connecting factor for the research of the Collaborative Research Center (CRC) 666 at the TechnischeUniversität Darmstadt (TUD). The superior goal of the CRC 666 is to generate bifurcated structures in integral design from steel sheet bands by means of novel production methods and techniques. The research work covers the complete product development process, starting with the definition of the requirements, over product design and manufacturing to product testing. The production line is based on a modular system to arrange the machine modules in different sequences. The processes in the production line of the CRC 666 are uncoiling, HSC edge milling, linear flow splitting, roll forming, HSC sheet milling, laser welding and sawing. The HSC sheet milling is an essential part of the production line. Towards other production processes like e. g. stamping the HSC

[Goertan 2009] Görtan, O., Vucic, D., Groche, P., Livatyali, H. Roll forming of branched profiles. Journal of Materials Processing Technology 209, S 5837-5844, 2009[Abele 2011] Abele, E., Jalizi B., Baklouti, F., Schiffler, A. Herstellung mul-tifunktionaler Strukturen – Mittels Integration des Zerspanprozesses in Walzprofilieranlagen. Zeitschrift für wirtschaftlichen Fabrikbetrieb (ZWF), Carl Hanser Verlag, München, 106, pp. 522-526, 2011 [Abele 2012a] Abele, E., Jalizi, B., Bayerer, A. HSC Fräsen in einer kon-tinuierlichen Fließfertigung – Aufbau eines Werkstückspannsystems zur

Milling; continuous flow production; HSCKEYWORDS

REFERENCES

milling process has the advantage to perform various continuous and discontinuous form elements. Furthermore the machined form elements can be chanced quickly and cost effective without additionally material requirements. Discontinuous in-line milling operations in continuous flow production of metal profiles are not state of the art. In case of a designated milling operation, it is done after the cutting process by separate machine tools. The integration of discontinuous milling operations into the continuous flow production enables the retrenchment of those downstream operations to save production time and costs. To perform the machining operation a high dynamic machining tool was developed. The milling “on the fly” is only possible through synchronizing the movement of the machine with the continuous feed of the sheet metal profile. Therefore the work piece feed is measured by a rotary encoder. The synchronization is done by superposing the work piece feed with the actual milling operation in the motion logic. Another challenge is the non-existing possibility to clamp the work piece due to its continuous feed. Thence the sheet metal profile is guided by a purpose built guiding system.

Positionierung kontinuierlich bewegter Blechprofile. wtWerkstattstechnik online, Springer-VDI-Verlag GmbH & Co. KG, Düsseldorf, Jahrgang 102, H. 9, 2012[Abele 2012b] Abele E., Bohn A., Jalizi B., Haydn M., Lommatzsch N., Coutandin P. Steigerung der Prozessqualität einer fliegenden HSC--Fräsmaschine – Maßnahmen zur Qualitätssicherung von Blechprofi-len in einer Fließfertigungsstraße. wtWerkstattstechnik online, Sprin-ger-VDI-Verlag GmbH & Co. KG, Düsseldorf, Jahrgang 102, H. 1/2, pp. 27-33, 2012


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HSM2014–14070

DEVELOPMENT OF FORCED COOLING USING MIST OF STRONG ALKALINE WATER FOR RESTRAINING THERMAL DEFORMATION ON A MACHINE TOOLI. Tanabe1*

1NTU, DEPT. OF MECHANICAL ENGINEERING, 1603–1 KAMITOMIOKA, NAGAOKA, NIIGATA, 940-2188 JAPAN


ABSTRACTIn the 21st century, as it is important to produce products with care for protecting the earth, a producer must be careful to conserve energy, save resources and reduce waste which pollutes environment. On the other hand, in case of a machine tool, much lubricating oil was used for smooth drive, electrical energy of forced cooling was used for high accuracy and much cutting oil was also used for lubrication and cooling. This is large problem for protecting the earth. Therefore behavior of a machine tool in mist of strong alkaline water were investigated and evaluated. Properties of strong alkaline water were firstly investigated for alkali-proof, corrosion and safty of health. Then the bench lathe was remodeled in the vessel with mist of

Paper in a journal: [Kaneko 2004] Kaneko, Y., Tanabe, I., Isobe, M., and Maeda, M. Development of a high precision lathe with countermeasure of environmental preservation for thermal deformation, Transactions of Japan Society of Mechanical Engineers (Series C), Vol. 70, No. 700, (2004), pp. 3611-3616 (in Japanese). [Simohira 1995] Simohira, S. Material science for crrosion and its protection, AGNE Gijutsu Center Inc., (1995), pp. 30-32, 255-257, 287-288 (in Japanese). [Tanabe 1999] Tanabe, I., Yamanaka, K., Mizutani, J. and Yamada, Y. A new design of lathe structure for reducing thermal deformation (Design of zero--center on three directions, self-compulsory cooling and design of thermal synchronism), Transactions of Japan Society of Mechanical Engineers (Series C), Vol. 65, No. 639, (1999), pp. 4508-4513 (in Japanese). [Tanabe 2000] Tanabe, I., Truong, H. M. and Yoshii, K. Turning with environ-ment-friendly cooling method using water evaporation (1st report, Cooling effect of water evaporation and its applicability to tool tip cooling), Transactions of Japan Society of Mechanical Engineers (Series C), Vol. 66, No. 643, (2000), pp. 1026–1030 (in Japanese). [Tanabe 2001] Tanabe, I., Matsushita, K. and Truong, H. M. Study on self-forced cooling for reducing thermal deformation of machine tool (Modeling of self--forced cooling and its applicability), Transactions of Japan Society of Mecha-nical Engineers (Series C), Vol. 67, No. 660, (2001), pp. 2713-2718 (in Japanese). [Tanabe and Truong 2001] Tanabe, I. and Truong, H. M. Cutting with an envi-ronment-friendly cooling method using water evaporation (Establishment of this cooling model and calculation of the suitable supply quantity of water), Transactions of Japan Society of Mechanical Engineers (Series C), Vol. 67, No. 664, (2001), pp. 4011-4016 (in Japanese).

Machine tool; thermal deformation; forced cooling; water evaporation; strong alkaline water; mistKEYWORDS

REFERENCES

strong alkaline water (pH12. 5), thermal deformation between the spindle and the tool post was measured for evaluation of accuracy. And cutting using CNC milling machine in the vessel with mist of strong alkaline water was performed for investigating the effect of water evaporation in the strong alkaline water. It is concluded from the results that; (1) Alkali-proof regarding several elements of a machine tool and safty of health were cleared in the experiment, (2) Thermal deformation of the bench lathe for bathing was very small in spite of no-forced cooling, (3) Accuracy of the machne tool was very good and the tool life was very long in spite of no-cutting oil, (4) Mist of strong alkaline was economical and eco-friendly.

[Tanabe 2003] Tanabe, I., Ikeda, S. and Urano, K. Estimation of optimum tem-perature for cooling oil on a spindle using inverse analysis of neural network (Effect of relearning), Transactions of Japan Society of Mechanical Engineers (Series C), Vol. 69, No. 679, (2003), pp. 819-824 (in Japanese). [Tanabe 2011] Tanabe, I., Ye, H. S., Iyama, T. and Abe, Y. Control of tool tempe-rature using neural network for machining work-piece with low thermal con-ductivity, Transactions of Japan Society of Mechanical Engineers (Series C), Vol. 77, No. 776, (2011), pp. 1556–1564 (in Japanese).

Technical reports or thesis: [e-Gov 2013] e-Gov, Ordinance related to calculation for carbon dioxide equi-valent greenhouse gas emissions with their business activities of specified emitters, Article 2 (2013), availablefrom< http://law.e-gov.go.jp/htmldata/H18/H18F15002002003.html> (accessed on 22 April, 2014) (in Japanese)[Greenhouse gas inventoryofficeof Japan 2014] Greenhouse gas inventory offi-ce of Japan, National GHGs Inventory Report of JAPAN (2014), availablefrom< http://www-gio.nies.go.jp/aboutghg/nir/2014/NIR-JPN-2014-v3.0_J.pdf> (accessed on 22 April, 2014) (in Japanese), [Ministry of the environment 2013] Ministry of the environment, Announce-ment of actual emission factor, adjusted emission per electricutility company in FY 2012 (2013), availablefrom<https://www.env.go.jp/press/press.php?seri-al=17512>(accessed on 22 April, 2014) (in Japanese). [Ministry of the environment 2014] Ministry of the environment, Calculati-on method and emission factor on calculation, report and publication system (2014), available from <http://ghg-santeikohyo.env.go.jp/files/calc/itiran.pdf> (accessed on 22 April, 2014) (in Japanese)


HSM2014–14015

HEAT FLUX MODELING DURING THE MACHINING OPERATIONS OF AN EXPLOSIVE MATERIAL – APPLICATION TO DRILLING

J. Bourderioux1*, T. Baizeau2, J. Saillard1

1CEA, COMMISSARIAT À L’ÉNERGIE ATOMIQUE ET AUX ÉNERGIES ALTERNATIVES, MONTS, FRANCE2LABOMAP, LABORATOIRE BOURGUIGNON DES MATÉRIAUX ET PROCÉDÉS, CLUNY, FRANCE


ABSTRACTThis study presents an inverse technic to estimate the heat partition and the temperature field in the tool/piece area during drilling operations. While most research works are focused on the temperature of the drill, in this study, we consider mainly the piece. The thermal instability of the material leads us to understand the heat flux partition in order to predict the temperature field in the piece and the chip knowing the cutting forces. Moreover, most works are conducted on metallic materials, whereas thermal degradation is observed during polymer composite materials drilling. To predict the temperature field, a thermal model will be created, heat sources and heat partition identified by experimental approaches. An inverse method is used to identify the transfer function between entering heat and temperature measured inside the drill head. During drilling both temperature and efforts will be recorded to estimate partition coefficients and heat sources. The main difficulties in thermal modeling of the cutting process are the estimation of the part of the mechanical power converted into heat sources at the interfaces and partition coefficients between each part of the system. For the heat source creation, most

[Davies 2007] Davies, M. A. On measurement of temperature in material removal process, Annals of the CIRP, vol. II, n° 56, pp. 581-604-2007. [Brinksmeier 2011] Brinksmeier, E., Fanfmann, S. and Rentsch, R. Drilling of composites and resulting surface integrity, CIRP Annals – Manufacturing technology, n° 60, pp. 57-60, 2011. [Merchant 1944] Merchand, M. E. American Society Mechanical Engineers, p. 158, 1944. [Zemzemi 2009] Zemzemi, Z. and Rech, J. Identification of friction model at tool chip workpiece interface in dry machining of AISI 4142 treated steel, Journal of materials processing technology, n° 209, pp. 3978-3990, 2009. [Battaglia 2001] Battaglia, J., Cois, O., Puigsegur, L., Oustaloup, O. Solving an heat conduction problem using an non-integer identified system, Inter-national Journal of Heat and Mass Tranfer, n° 144, pp. 2671-2680, 2001. [Huang 1999] Huang, C. H. and Wang, S. -P. A three-dimensional inverse heat

Drilling; heat flux; polymer; modelingKEYWORDS

REFERENCES

authors consider that about 99% of the mechanical energy needed to cut the material is converted into heat. This experimental value represents the biggest hypothesis for the project that may be checked. The heat partition at production interfaces is modeled analytically considering a perfect contact area and the continuity of the temperature at the interface by Reznikov. He considered the effect of chip velocity and the time duration of the contactin an analytical equation. Other authors proposed experimental models. By monitoring the temperature in a tool and the cutting forces during a drill, a model linking mechanical power and heat sources will be developed and added to a 2D-axysymetrique modelling of the process. By adding a partition model characterized experimentally, the simulation will be able to provide a temperature map of the piece and the cutting edge of the tool. A test bench base on Battaglia’s work is used to identify the instrumented drill. All tests are performed on a milling machine and on a non – energetic material (polymer) at the laboratory in order to set up the MATLab developed simulation. The temperature measurement is performed with thermo-resistances. Forces are recorded with a Kistler 9256A piezoelectric force stage.

conduction problem in estimation surface heat flux by conjugate gradient method, Int. Journal of Heat and Mass Transfer, n° 42, pp. 3347-3403, 1999. [Huang 2000] Huang, C. H., Chen, W. A three-dimensional inverse forced convection problem in estimating surface heat flux by conjugate gradient method, Int. Journal of Heat and Mass Transfer, n° 143, pp. 3171-3181, 2000. [Huang 2007] Huang, C. -H., Jan, L. -C., Li, R., Shih, A. J. A three-dimensional inverse problem in estimating the applied heat flux of a titanium drilling – Theoretical and experimental studies, International Journal of Heat and Mass Transfer, n° 150, pp. 3265-3277, 2007. [De Sousa 2012] De Sousa, P. F. Estimation of heat flux and temperature field during drilling process using dynamic observers based on Green’s function, Applied Thermal Engineering, n° 48, pp. 144–154, 2012. [Reznikov 1981] Reznikov, A. Thermophysical Aspects of Metal Cutting Processes, Machinostroenie, Moscow, 1981.


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HSM2014–14025

TRAJECTORIES IN LASER MACHINING CERAMICS: THERMAL MODEL TO CONTROL MATERIAL REMOVE RATE

A. Demarbaix1*, F. Ducobu1, E. Riviére-Lorphévre1, E. Filippi1, F. Petit2, N. Preux2

1UNIVERSITY OF MONS, FACULTY OF ENGINEERING, MACHINE DESIGN AND PRODUCTION ENGINEERING DEPARTMENT, MONS, BELGIUM2ENVIRONMENTAL MATERIALS RESEARCH ASSOCIATION, R&D SUPPORT, MONS, BELGIUM


ABSTRACTCeramic machining faces a lot of practical problems due to its mechanical properties leading to high cutting fortes (yield strength), fast tool wear (hardness) and problems to achieve given tolerances (brittle behavior). Laser machining is an attractive alternative to conventional machining techniques because this technology is a non-contact, non-abrasive one which eliminates tool wear, cutting forces, vibration.The machining of the Yttria-stabilized tetragonal zirconia polycrtistalline (Y-TZP) ceramics which is commonly used in the dental restoration was studied. Laser machining is a method allowing building of a ceramic piece layer by layer by removing material. However, the problem of this method is to master material removal rate. In fact, the thermal effects plays an important role during laser machining because of appearance of hot spot that could cause an uncontrolled material removal rate. Results of these investigations have compared several paths to predict the better trajectory allowed for a steady rate. To do this, a first step of the laser machining process is modeled with the finite elements method. A thermal model of a moving heat source is developed with the software ABAQUS v6. 11. The power

[Filser 2001] Filser, F. T. Direct Ceramic Machining of ceramic dental resto-rations. Diss ETH No. 14088. Zurich: Swiss federal institute of technology Zurich, 2001. [Denry 2008] Denry, I. and Kelly, J. R. State of the art of zirconia for dental appli-cations. Dental Materials; March 2008, Vol. 24, Issue 3, pp 299-307. [Vora 2013] Vora, H. D., Santhananakrishan, S., Harimkar, S. P., Boetcher, S. K. S. and Dahotre, N. B. One-dimensional multipulse laser machining of structural alumina: evolution of surface topography. The International Journal of Advanced Manufacturing Technology, September 2013, Vol. 68, Issue 1-4, pp 69-83. [Carslaw 1959] Carslaw, H. S., and Jaeger, J. C. Conduction of heat in solids. Oxford at the Clarendon press 1959. [Darmadi 2011] Darmadi, D., Norrish, J., and Tieu, A. K. Analytic and Finite

Laser machining; ceramics; trajectories; thermal model; paths; machining strategyKEYWORDS

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output of the YAG laser, the repetition rate, its spot diameter and the scanning speed are implemented in this model. Several paths were studied (Zig-Zag and Contour parallel) and compared with the reference laser machining strategy (unidirectional-Zig). A method based on the heating time and the temperature map on a path has been developed to compare these different trajectories. Our simulations show that when heating a pocket, hot spots with contour parallel trajectory are lower than the maximum of reference strategy. By contrast, the Zig-Zag strategy is avoided due to the apparition of a hot spot. Considering heating time, contour parallel strategy is better than the reference strategy (Zig) because the laser beam must be stopped to be again on one new trajectory. But this trajectory would be preferable for machining of pocket without island. Finally, an island of different sizes was implemented in pocket model. The contour parallel strategy remains more interesting than the Zig strategy. Indeed, the hot spots are again lower than hot spots of Zig trajectory. The heating time of the Zig strategy is more important than the contour parallel strategy. This modeling approach could be used to others techniques as cladding technique and selective laser melting of metals.

Element Solutions for Temperature Profiles in Welding using VariedHeat Source Models. World Academy of Science, Engineering and Technology, 81, pp 154–162. [Piekarska 2010] Piekarska, W., Kubiak, M. and Saternus, Z. Application of Abaqus to analysis of the temperature field in elements heated by moving heat sources. Archive of foundry engineering, July 2010, Vol. 10, Issue 4/2010, pp 177–182, ISSN 18973310[Kaldos 2004] Kaldos, A., Pieper, H. J., Wolf, E., Krause, M. Laser machining in die making—a modern rapid tooling process. Journal of Materials Processing Technology, November 2004, Vol. 155–156, pp 1815–1820. [Heyl 2001] Heyl, P., Thomas Olschewski, T., and Wijnaendts, R. W. Manufactu-ring of 3D structures for micro-tools using laser ablation. Microelectronic Engineering, September 2001, Vol. 57-58, pp 775-780.


HSM2014–14027

MONITORING OF CUTTING PROCESS IN END MILLING OF HARD AND BRITTLE MATERIALS

K. Shimana1*, E. Kondo2, A. Yoshidome1, S. Yamashita1, Y. Kawano1

1KAGOSHIMA NATIONAL COLLEGE OF TECHNOLOGY, DEPARTMENT OF ELECTRONIC CONTROL ENGINEERING, KIRISHIMA, JAPAN2KAGOSHIMA UNIVERSITY, GRADUATE SCHOOL OF SCIENCE AND ENGINEERING, KAGOSHIMA, JAPAN


ABSTRACTMicrofabrication techniques are indispensable to manufacturing small parts of the tablet-type device, the cellular phone, and so on. In recent years, microfabrication by using a small diameter end mill has been used widely in manufacturing process of optical components and semiconductor because high speed machining by using a small diameter end-mill has been put into practical use. Therefore, since the effect of cutting edge on the machining accuracy is very large, it is very important to detect the state of small diameter end mill in real time. However, since the size of tool wear of small diameter end mill are very small, it is difficult to detect the state of tool. On the other hand, glass materials are widely used for the optical components in recent years. However, glass materials are difficult to machine because they are hard and brittle materials. Tool wear of cutting tool is heavy in the glass

[Lai 2008] Lai, X., et al. Modeling and Analysis of Micro Scale Milling Conside-ring Size Effect, Micro Cutter Edge Radius and Minimum Chip Thickness. Int. J. Mach. Tools Manufact., 2008, 48, pp. 1–14. ISSN 08906955[Rahman 2001] Rahman, M., et al. Micro Milling of Pure Copper. J. Mater. Proc. Tech., 2001, 116, pp. 39-43. ISSN 09240136[Jemielniak 2008] Jemielniak, K., et al. Application of AE and Cutting Force Sig-nals in Tool Condition Monitoring in Micro-Milling. CIRP J. Manuf. Sci. Technol., 2008, 1, pp. 97–102. ISSN 17555817

Glass milling; micromachining; brittle materials; end millKEYWORDS

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milling. In addition, the glass materials must be machined as the ductile mode cutting without brittle cracks. The purpose of this study is to propose an effective method to detect the state of the cutting tool in hard brittle materials in real time. For this purpose, cutting tests were performed in order to investigate the effective parameters for monitoring the micro tool wear in glass milling. As a result, it was found in the experiments that the edge of the groove is initially machined with brittle cracks, but as the cutting time increases, the edge of the groove is machined without brittle cracks. Furthermore, the cutting force was found to increase with increasing tool wear. The cutting force component Fx is more closely correlated with tool wear. However, the amplitude of the cutting force is very small and small vibrations of the machine tools have a significant influence on the monitoring.

[Malekian 2009] Malekian, M., et al. Modeling of Dynamic Micro-Milling Cutting Forces. Int. J. Mach. Tools Manufact., 2009, 49, pp. 586-598. ISSN 08906955[Matsumura 2005] Matsumura, T., et al. A Study on Cutting Force in the Mi-lling Process of Glass. J. Manuf. Proc., 2005, 7-2, pp. 102–108. ISSN 15266125[Ono 2008] Ono, T., et al. Influence of Tool Inclination on Brittle Fracture in Glass Cutting with Ball End Mills. J. Mater. Proc. Tech., 2008, 202, pp. 61-69. ISSN 09240136


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HSM2014–14030

INVESTIGATION ON MINIMIZATION OF CHATTER VIBRATION IN THIN-WALL MACHINING OF AL7075-T651

J. Y. Koo1, M. H. Cho1, H. Kim1, D. H. Ye1, J. S. Kim2*

1SCHOOL OF MECHANICAL ENGINEERING, PUSAN NATIONAL UNIVERSITY, BUSAN, REPUBLIC OF KOREA2SCHOOL OF MECHANICAL ENGINEERING, ERC/NSDM, PUSAN NATIONAL UNIVERSITY, BUSAN, REPUBLIC OF KOREA


ABSTRACTThis paper presents cutting conditions to minimize chatter vibration and machining deformation. Also, a method for avoiding chatter vibration generated during machining is presented. Chatter vibration not only degrades surface integrity but also reduces productivity by shortening tool-life. Furthermore, a thin-wall structure is easy to be deformed by cutting forces acted during machining, machining accuracy degrades by that. Therefore, chatter

[Juijerm 2000] Juijerm, P. and Altenberger, I. Alloys, Theory and Applicati-ons. Netherlands: Kluwer Academic Publishers, 2000. [Matweb] Matweb n. d<http://www.matweb.com>[Odeshi 2013] Odeshi, A. G., Adesola, A. O. and Badmos, A. Y. Failure of AA 6061 and 2099 aluminum alloys under dynamic shock loading. Engineering Failure Analysis, 2013, 35, pp302-314. [Rai 2008] Rai, J. K. and Xirouchakis, P. Finite element method based ma-chining simulation environment for analyzing part errors induced during milling of thin-walled components. Int. Journal of Machine Tool and Ma-nuf., 2008, 48, pp 629-643.

Thin-wall machining; high-speed machining; chatter vibration; machining productivity; surface integrity KEYWORDS

REFERENCES

vibration and machining deformation should be minimized in order to enhance machining quality and productivity. In this study, cutting forces and acceleration are measured by a dynamometer and an accelerometer during a high-speed machining of thin-wall shape. Chatter vibration occurrence is sensed by frequency analysis on acceleration signals and analysis on machined surface.

[Seguy 2008] Seguy, S., Dessein, G. and Arnaud, L. Surface roughness va-riation of thin wall milling, related to modal Interactions. Int. Journal of Machine Tools and Manuf., 2008, 48, pp 261–274. [Totis 2014] Totis, G. et al. Efficient evaluation of process stability in milling with Spindle Speed Variation by using the Chebyshev Collocation Method. Journal of Sound and Vibration, 2014, 333, pp 646–668. [Vakondios 2012] Vakondios, D. et al. Influence of milling strategy on the surface roughness in ball end milling of the aluminum alloy Al7075-T6. Measurement, 2012, 45, pp 1480–1488


HSM2014–14037

TIME DOMAIN CRITERIA FOR CONTROLLER PARAMETERIZATION BY SIMULATION BASED OPTIMIZATION

K. Hipp1*, A. Hellmich1, H. Schlegel1, R. Neugebauer1

1TECHNISCHE UNIVERSITAET CHEMNITZ, FACULTY OF MECHANICAL ENGINEERING, PROFESSORSHIP FOR MACHINE TOOLS AND FORMING TECHNOLOGY, REICHENHAINER STR. 70, 09126 CHEMNITZ, GERMANY


ABSTRACTController parameterization of drive systems is commonly performed by applying basic tuning rules or by carrying out not comprehensible design automatisms which are integrated in the control system. For the cascaded position control, this is done successively, from the inner to the outer loop. An alternative approach is to parameterize the typical controller cascade, which is widely used in standard industrial controllers, in one step by using established methods within the field of operations research. Especially the application of the so-called “simulation-based optimization” (SBO) is auspicious for control engineering, particularly for controller parameterization. Advantages for the user are, for example, the opportunity of defining specific restrictions concerning the desired controller parameterization or the possibility to directly process non-linear systems without approximations. Hence, this can also include the correct consideration of friction, additional filters in the cascade or controller structure extensions like the Advanced Position Control (APC). A main component of the SBO is the objective function, which evaluates a current solution. Therefore, it has a large influence on the results of the optimization and, as a consequence, on the quality of the determined controller setting. Intention of the current research is to investigate the best way to

[Åström 2008] Åström, K. J. and Murray, R. M. Feedback Systems, 2008, Prin-ceton University Press, ISBN 0691135762[Carson 1997] Carson, Y. and Maria, A. Simulation Optimization: Methods and Applications, Winter Simulation Conference, 1997[Goyal 2007] Goyal, S and Bakshi, U. Principles of Control Systems, 7 ed., Technical Publications, 2007[Hipp 2014] Hipp et al. Criteria for controller parameterization in the fre-quency domain by simulation based optimization, Mechatronics 2014, 2014 (to be published)[Hofmann 2012] Hofmann, S. Identifikation parametrischer Modelle für geregelte elektromechanische Achsen mit modifizierter sukzessiverPolkom-pensation, Dissertation thesis, Technische Universitaet Chemnitz, 2012 (in German). [Kennedy 1995] Kennedy, J. and Eberhart, R. Particle Swarm Optimization,” Proceedings of IEEE International Conference on Neural Networks, 1995[Köchel 2009] Köchel, P. Simulation Optimisation: Approaches, Examples, and Experiences, TU Chemnitz, 2009. [Lutz 2007] Lutz, H. and Wendt, W., J. Taschenbuch der Regelung-stechnik: Mit MATLAB und Simulink, 2007, Verlag Harri Deutsch, ISBN 9783817118076 (in German)

Controller parameterization; simulation based optimization; evaluation criteria; optimization criteria; time domainKEYWORDS

REFERENCES

formulate objective functions. Hence, in literature a various number of different evaluation criteria in the time domain can be found. Examples are the absolute control area or the time weighted square control area. However their influence on the optimization results is not well researched. As a consequence in this paper different optimization criteria in the time domain are presented and compared with respect to their applicability for the controller design based on SBO for test plants. After an introduction, the paper describes the basic principles of the simulation based optimization including the application for controller parameterization. Subsequently, the methodology of operation of the used hybrid optimizer is stated followed by an introduction of different optimization criteria in the time domain introduced. The main part of the paper deals with the evaluation of the optimization criteria for the simulation based optimization. Both, the influence to the optimization results and the performance of the optimization are discussed. To proof the applicability of the optimization criteria, it is demonstrated how the results from theoretical plant models perform with a test rig, modelled by a two mass system with friction characteristic. Finally, the results of the determined controller parameters on the test rig are presented. The paper closes with a summary and an outlook.

[MATLAB 2013] The MathWorks Inc., Optimization Toolbox™ – User’s Guide, 2013b[Nelder 1965] Nelder, J. A Simplex Method for Function Minimization, Computer Journal Advance, 1965[Neugebauer 2011] Neugebauer et al. Application of simulation based optimization methods for the controller parameterization considering defi-nable constraints, VDI Mechatronics 2011, Dresden, Germany, 2011, ISBN 9783000338922[Neugebauer 2012] Neugebauer et al. Increased Performance of a Hybrid Optimizer for Simulation Based Controller Parameterization, Journal of Automation, Mobile Robotics & Intelligent Systems, 2012, Vol. 6, No. 1., eISSN 2080-2145[Pötzsch 2012] Pötzsch, A. Ausarbeitung, Realisierung sowie Bewertung von Leistungskriterien und Nebenbedingungen für die simulationsbasierte Optimierung für Reglerstrukturen, TU Chemnitz, 2012 (in German). [Shinners 1992] Shinners, S. M. Modern Control System Theory and Design, 2 ed., John Wiley & Sons, 1992, ISBN 0471550086[Tekin 2004] Tekin, E. and Sabuncuoglu, I. Simulation optimization: A compre-hensive review, ” vol. 36, no. 11, 2004


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HSM2014–14043

ANALYSIS OF MACHINING CONFIGURATIONS WITH BALL-END MILLS IN ORDER TO FINISH PARTS MADE BY EBM AND COMPARISON WITH NUMERICAL MODELA. Dolimont1*, E. Riviére-Lorphévre1, E. Filippi1

1UNIVERSITY OF MONS, FACULTY OF ENGINEERING, MACHINE DESIGN AND PRODUCTION ENGINEERING DEPARTMENT, 20, PLACE DU PARC, MONS 7000, BELGIUM


ABSTRACTDuring the last 25 years additive manufacturing technologies have continued to grow. In the future, we can expect a continuation of this rapid expansion not only to make prototypes but also and mainly to produce finished parts in small series. The EBM (Electron Beam Melting) method is one of those technologies. It allows the manufacturing of fully dense parts layer by layer from a non-magnetic metal powder. With rapid prototyping process, the part was built with material like polymers and it was just a visualization step in the production process. The EBM isn’t only a visualization step in the production cycle. It allows the fabrication of parts with good mechanical properties directly by a CAD model. In the future this process will be more used for the small series production. As an example, it’s now possible to produce prostheses (jaw, hip, thumbs, …) adapted to the morphology of the patients. But a finishing operation is still missing. Until the present day there is no quality standard for parts produced by EBM. This process has some limitations. It leads to a pore surface quality. So post processing operations are required in order to obtain good characteristics. In this study, the finishing of parts made by EBM will be performed

[Sirris 2013] Monfort-Windels, F. Evolution des techniques de fabrication additive, Sirris, Juillet 2013, [Boujelbene 2000] Boujelbene, M., Brenier, B., Fabre, A., et Moisan, A. Etat de surface des pièces de formes complexes fraisées en bout sur centre d’usinage. TCMM Editura Technica, Bucaresti, Romania, 2000, 41, pp. 215-220, [Duc 1998] Duc, E. Usinage de formes gauches, Contribution à l’amélioration de la qualité des trajectoires d’usinage, Thèse de l’Ecole Normale Supérieure de Cachan, France, 1998[Ralph 1993] Ralph Ip W. L. and Martin Loftus, The application of an inclined end mill machining strategy on 3-axis machining centres. Int. J. Mach. Tools Manufact., 33, No. 2, pp. 115–133. 1993[Schulz 1995] Schulz, H. and Hock, St. High speed Milling of dies and Mouls Production. 2nd International conference on High Speed Machining. Darmstadt, Germany 1995. [Boujelbene 2001] Boujelbene, M., Fabre, A. Amélioration de l’état de surface microgéométrique en rainurage cinq axes, XV Congrès Français de Méca-nique, Nancy, 7 septembre, 2001. [Rubio 1993] Rubio, W. Génération de trajectoire du centre de l’outil pour l’usinage de surfaces complexes sur machines à trois et cinq axes, Thèse de doctorat de l’université Paul Sabatier, France, 1993[Murr 2009] Murr, L. E., Esquivel, E. V., Quinones, S. A., Gaytan, S. M., Lopez, M. I., Martinez, E. Y., Medina, F., Hernandez, D. H., Martinez, E., Martinez, J. L., Stafford, S. W., Brown, D. K., Hoppe, T., Meyers, W., Lindhe, U. and Wicker, R. B. Microstructure and mechanial properties of electron beam

Multiaxis machining; ball-end mill; tool orientation; cutting force model; simulationsKEYWORDS

REFERENCES

by multiaxis milling. This technology is typically used to produce free-form surfaces. The geometry of the tool that is traditionally used for this type of operation is ball nose. The multiaxis milling offers the possibility of inclination of the tool according to two angles. That results in a variety of geometric configurations. But therefore it is necessary to compute the most appropriate settings. Furthermore, a software that had been developed by the Machine Design and Production Engineering Department of the Faculty of Engineering of the University of Mons allows notably to determine cutting forces. There are 3 aspects coupled in this software: a dynamic model, a geometric model and an effort model. This study will be conducted in first time on Ck45 steel with a ball-end mill. Different configurations will be tested by varying the angle of inclination perpendicular to the advance. A measurement of the cutting forces depending on the tilt angle will be carried out to determine the optimum angle of inclination for the multiaxis machining. In second step, we will compare the cutting forces measured experimentally with those obtained by the Dystamill software.

rapid manufactured Ti-6Al-4V biomedical prototypes compared to wrou-ghtTi-6Al-4V. Materials characterization, 2009. 60: 96–105[Karlsson 2013] Joakim Karlsson, Anders Snis, Hakan Engqvist, and Jukka Lausmaa. Characterization and comparison of materials produced by electron beam melting (ebm) of two different Ti-6Al-4V powder fractions. Journal of Materials Processing Technology, 2013. [Koike 2011] Mari Koike, Preston Greer, Kelly Owen, Guo Lilly, Lawrence E. Murr, Sara M. Gaytan, Edwin Martinez, and Toru Okabe. Evaluation of tita-nium alloys fabricated using rapid prototyping technologies electron beam melting and laser beam melting. Materials 2011, October 2011, pages 1776–1792. [Mahale 2009] Tushar Ramkrishna Mahale. Electron Beam Melting of advanced Materials and structures. Faculty of North Carolina State Uni-versity, 2009. [Denkena 2013] Berend Denkena, Ferdinand Hollman. Process machine interactions: prediction and manipulation of interactions between manu-facturing processes and machine tool structure. Springe lecture notes in production engineering, 2013. [Engin 2001] Engin, S., Altintas, Y. Mechanics and dynamics of general milling cutters. Part I: helical end mills. Int. J. Mach. Tools Manufact., 41, pp. 2195-2212. 2001[Riviere 2009] Riviére-Lorphévre, E. and Filippi, E. Mechanistic cutting force model parameters evaluation in milling taking cutter radial runout into account Int. J. Adv. Manuf. Technol., 2009, 45: 8, 8–15


HSM2014–14054

cBN-BASED CUTTING TOOLS FOR HIGH-SPEED CUTTING OF HARDENED STEEL AND CAST IRON GRADES

O. Bulatov1, N. Korableva1*, N. Kovelenov1, V. Ponomarenko1, I. Kuznetsova1

1VIRIAL LTD., ENGELSA 27 (BLDG. 143A), SAINT-PETERSBURG, 194156, RUSSIA


ABSTRACTConventionally in semi-finishing and finishing of hardened steels and cast iron grades the cutting inserts of choice are those based on cubic boron nitride (cBN), with 75- 80vol. %cBN contents. The present paper is aimed at reduction of the volume fraction of expensive cBN material in a composite cutting ceramics without degrading the cutting performance. To this end various ceramic additives were added into the composition. The cBN powders (d50 ~ 6 μm), oxide powders (d50 ~ 0. 7 μm), and nitride powders (d50 ~ 1 μm) were used as starting powders. Additive-containing composite ceramics in the cBN system were processed by HPHT technique in the anvil cell apparatus at temperatures of 1450÷1550 °C and pressures below 4. 0 GPa. Microstructural characterization of the developed materials in scanning electron microscope showed that the ultrahard phase was homogeneously distributed in the composite. The material samples failed in a mixed intergranular+transgranular mode. Mechanical and physical characterization was performed as per

[Angseryd 2009] Angseryd, J., et al. Detailed microstructure of a cBN based cutting tool material. International Journal of Refractory Metals and Hard Materials, November 2009, No. 27, pp. 249-255. [Bartarya 2012] Bartarya, G., Choudhury, S. K. State of the art in hard turning. Review Article International Journal of Machine Tools and Manufacture, February 2012, Vol. 53, Issue 1, pp. 1–14. [Benga 2001] Benga, G., Abrao, A. Turning of hardened 100cr6 bearing steel with ceramic and PCBN cutting tools. Original research article. Journal of materials processing technology, December 2003, Vol. 143–144, pp. 237-241. [Klimczyk 2011] Klimczyk, P. et al. Cubic boron nitride based composites for cutting application. J. of Achievements in Materials and Manufacturing Engi-neering, February 2011, Vol. 44, No. 2, pp. 198-204. [Klimenko 2009] Klimenko, S. andKopeykina, M. Coated edge tools, with poly-crystalline ultrahard materials based on cubic boron nitride. Tool World journal, March 2009, Vol. 43, No. 3, pp. 13–15(in Russian). [Klimenko 2012] Klimenko, S. et al. The development and application of ce-ramic cutting tool based on the superhard structured composites. Tool World journal, December 2012, No. 12, pp. 127–135. ISSN–1817-2997 (in Russian).

Composite ceramics; polycrystalline cubic boron nitride; silicon nitride; alumina; cutting tool; semi-finishing and finish turning; PVD coating; AlTiN

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REFERENCES

applicable ISO standards. The Vickers’ hardness of the 40 vol. % cBN material was 21. 3±2. 8 GPa, while its fracture toughness was 6. 6±0. 9 MPa*m1/2. The performance of the experimental RNMN 09Т300 inserts (as per ISO513) was tested by using flank wear criterion in machining of hardened steel (similar to 1. 2419, hardness: 60 HRC) and grey cast iron (similar to GG20); the cutting tests results were compared to those of reference commercial inserts with 80vol. %cBN.Flank wear of developed inserts when cutting hardened steel was 0. 10 mm after 1. 3 min. of cutting, which is slightly more than that of reference inserts (0. 08 mm). For cast iron cutting tests the developed composite demonstrated milder wear (0. 09 mm), as compared to reference commercial insert (0. 12 mm). The research demonstrated the viability of processing composite ceramics with reduced ultra-hard cBN phase contents. Cutting inserts based on the developed material may be used for semi-finishing and finish turning of hardened steels and cast iron grades.

[Novikova 2006] Novikova, N. Ultrahard materials. Processing and applications Monograph in 6 volumes, Kyiv, IUHM V. Bakul Institute for Superhard Materials Publishers, 2006, Vol. 6(in Russian). [Ran 2008] Ran, Lv. et al. High pressure sintering of cubic boron nitride com-pacts with Al andAlN, Diamond and Related Materials, 2008, Vol. 17, pp. 2062-2066. [Rong 2002] Rong, X. et al. High-pressure sintering of cBN-TiN-Al composite for cutting tool application. Journal Diamond and RelatedMaterials, November 2002, No. 11, pp. 280-286. [Rumyantsev 2010] Rumyantsev, V. et al. Tool ceramics based on nanosized Si3N4 powders. The Proceedings of the World Powder Metallurgy Congress and Exhibition PM2010: Florence, 2010, Vol. 3, pp. 591-595. [Thamizhmanii 2008] Thamizhmanii, S., et al. Surface roughness analyses on hard martensitic stainless steel byturning. Journal of Achievements in Materials and Manufacturing Engineering, February 2008, No. 26, pp. 139–142. [Zubarev 2008] Zubarev, Yu. Modern tool materials. St-Petersburg: Lan‘Pub-lishers, 2008(in Russian).


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HSM2014–14055

OPTIMIZATION OF DESIGN, PROCESSING, AND CUTTING PERFORMANCE DIAGNOSTICS OF THE CUTTING INSERTS BASED ON CERAMIC COMPOSITE MATERIALSS. Bolotskikh1*, Ya. Diatlova1, N. Kovelenov1, S. Mikhailov1

1VIRIAL LTD., ENGELSA 27, PO BOX 52, 194156, SAINT-PETERSBURG, RUSSIA


ABSTRACTAchieving efficient high-speed cutting depends on the development of the tools with radically new performance parameters. The present paper is aimed at improving the cutting performance of the composite ceramic–based inserts via development of finer, more uniform nanostructured composites, using high-speed field-assisted sintering technique, as well as via design optimization and research based on new accelerated procedure for cutting performance diagnostics. To this end, the mixed Al2O3-ZrO2-TiCN – based ceramics was doped with nanopowders and submicron Al2O3 powders that effectively limited grain growth. Similar research was also carried out for nitride-based ceramics. The effect of the nanopowder doping was most pronounced when spark plasma sintering (SPS) was used for lab-scale consolidation tests. The development of the series production process for indexable faced cutting inserts based on ceramic nanocomposites via FAST/SPS technique shall be continued under the research project EUROSTARS E!6237. (SeProFAST)Improved strength of the cutting inserts enables new opportunities for optimization of the tool

[Filimonov 1993] Filimonov, L., Petrashina, L. Chip forming features under localized shear conditions in high-speed cutting (in Russian). Vestnik Mashi-nostroyenia, 1993, No. 5-6, pp. 23-25. [Groza 2003] Groza, J. R., Zavaliangos, A. Nanostructured. Bulk solids by field activated sintering. Journal of Review of Advanced Material Science, 2003, Vol. 5, No. 1, pp 24—33. [Guo 2007] Guo, Z. et al. Microstructure and Electrical Properties of Si3N4/TiN Composites Sintered by Hot Pressing and Spark Plasma Sintering. Ceramics International, 2007, Vol. 33, pp 1223–1229. [Mikhailov 2001] Mikhailov, S., Evolution of notions about physical nature of formation of various chip forms and types during metal cutting (in Russian). Sistemyi Analyz. Teoria i Praktika. Collective research papers. – Kostroma, Kostroma State Technical University publishers, 2001, pp. 155–161. [Mikhailov 2005] Mikhailov, S., Modelling and optimization of the chip forming process during cutting of different materials (in Russian): Monograph, Kostroma, Kostroma State Technical University publishers, 2005, 180 p.

Oxide composite ceramics; nanosized powders; high-speed sintering; high-speed cutting; chip formation; cutting wedge stresses;complex-shaped tools; accelerated cutting performance diagnostic methods

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geometry. Research shows that increasing cutting speed leads to changes in chip formation process: continuously forming flow chip becomes discontinuous, which is attributable to the localized plastic deformation and high temperature in the narrow shear zone. Stabilization of the contact processes on the rake edge of the tool via using special sub-sized chip-leading elements led to decrease or complete elimination of the possibility for generation of the fluctuating cyclical stresses near the cutting edge, which resulted in improved tool performance. To speed up the cutting performance evaluation of the tools there was developed an engineering procedure for accelerated identification of the optimized cutting parameters to match the maximum wear resistnace of the cutting tool. The said procedure is based on the force measurement and echo-based vibration testing of the tool quality by using precision piezoelectric sensors. The developed procedure was used for identification of the optimal designs and processing techniques for cutting inserts, as well as for evaluation of the wear-resistant coatings, and accelerated characterization of the cutting performance of the tools.

[Mikhailov 2006] Mikhailov, S. Evolution of theory for chip formation and fracture in order to improve efficiency of machining of ductile materials – (in Russian): DrSc Thesis: Rybinsk Aviation Technology University publishers, Rybinsk, 2006 – 450 p. [Mikhailov 2014]. Mikhailov, S., Kovelenov, N., Bolotskikh, S. Development of experimental procedure for accelerated characterization of cutting properties of the tool (in Russian). Izvestiya Samarskogo Nauchnogo Centra Rossiyskoy Akademii Nauk, 2014, Vol. 16, No. 1(2), pp. 404-409. [Nygren 2004] Nygren, M. and Shen, Z. Spark Z. Plasma Sintering: Possibi-lities and Limitations. Key Engineering Materials, 2004, Vols. 264—268, pp. 719-724. [Perera 1998] Perera, D. S., et al. Comparative study of fabrication of Si3N4/SiC composites by spark plasma sintering and hot isostatic pressing. Journal of the European Ceramic Society, 1998, Vol. 18, No. 4, pp 401–404.


HSM2014–14060

HiPIMS COATED CARBIDES WITH HIGH ADHESIVE STRENGTH FOR HARD MACHINING

E. Uhlmann1, B. Stawiszynski1*, C. Leyens2, S. Heinze2

1IWF, INSTITUTE OF MACHINE TOOLS AND FACTORY MANAGEMENT, TECHNICAL UNIVERSITY BERLIN, BERLIN, GERMANY2IFWW, INSTITUTE OF MATERIAL SCIENCE, TECHNISCHEUNIVERSITÄT DRESDEN, DRESDEN, GERMANY


ABSTRACTHard processing is defined as the machining of ferrous materials with a hardness of at least 50 HRC. Due to the possibility of the substitution of grinding processes, hard processing has grown in importance in recent years. Fundamental to this was the development of heat and wear resistant cutting materials. The turning of hardened steel is currently possible with cubic boron nitride and ceramic tools. However, hard metals offer a higher versatility and optimization potential. With a choice of different substrate compositions, grain sizes, micro and macro geometry and hard coatings, modern manufacturing technology has a large range of tool combinations. By progressive developments in the field of PVD coating technology it is now possible to deposit hard, dense and smooth layers with sufficient toughness by the application of the HiPIMS process. In

[Klocke 2008] Klocke, F.; Koenig, W. Fertigungsverfahren 1. 8th edition. Berlin: Springer Publisher, 2008, pp 297. [Koch 1996] Koch K. -F. Technologie des Hochpräzisions-Hartdrehens. Aachen: Shaker Publisher, RWTH Aachen University, Dissertation, 1996. [Denkena 2011] Denkena, B., Toenshoff, H. K. Spanen – Grundlagen. 3rd edition. Heidelberg: Springer -Publisher, 2011, pp 213. [Ackerschott 1989] Ackerschott, G. Grundlagen der Zerspanung einsatzgehär-teter Stähle mit geometrisch bestimmter Schneide. Aachen, RWTH Aachen University, Dissertation, 1989. [Kouznetsov 1999] Kouznetsov, V., Macak, K., Schneider, J. A novel pulsed magnetron sputter technique utilizing very high target power densities. Surface andCoatings Technology 122 (1999), pp 290. [Bandorf 2009] Bandorf, R., Vergoehl, M., Werner, O. HiPIMS – Technologie und Anwendungsfelder. Vacuum in Research and Practice 21 (2009) No. 1, Braun-schweig, pp 32.

Hard processing; turning; HiPIMS; hard coatings; wear testsKEYWORDS

REFERENCES

this contribution cutting inserts with wear resistant hard metal substrates in combination with varying TiAlNHiPIMS films are studied with regards to their wear behavior in model wear test rigs. The tools are tested not with regards to the on individual wear mechanisms, the layer adhesion compared with conventional DC-PVD tools is also evaluated afterwards. After evaluating the wear of the HiPIMS layers a promising film-substrate system for the cutting tests is selected. In the context of straight cylindrical turning, tool life tests of hardened steel with approximately 53 to 55 HRC were undertaken and the process performance of these tools evaluated. The use and wear behavior of the HiPIMS tools is compared to the behavior of the DC PVD coated inserts. The objective is to establish the HiPIMS layer for industrial usage in the hard machining process.

[Bobzin 2009] Bobzin, K., Bagcivan, B., Immich, P., Bolz, S., Fuß, H., Cremer, R. Properties of (Ti, Al, Si) N coatings for High Demanding Metal Cutting Appli-cations Deposited by HPPMS in to Industrial Coating Unit, Plasma Process. Polym. (2009) 6, Aachen, pp 124. [Bobzin 2010] Bobzin, K., Bagcivan, B., Ewering, M. Hartstoffschichten der Zukunft. Vacuum in Research and Practice 22 (2010) No. 6, Aachen, pp 31. [Bouzakis 2010] Bouzakis, K. D., Skordaris, G., Gerardis, S., Katirzoglou, G., Makrimallakis , S., Pappa, M., Bolz, S., Koelker, W. The effect of substrates and pretreatments HPPMS -deposited adhesive inter- layers ' materials on the cutting performance of coated cemented carbide inserts . CIRP Annals – Manufacturing Technology 59 (2010), Wuerselen, pp 73. [Uhlmann 2011] Uhlmann, E., Richarz, S., Fuentes, J. Hartdrehen von PM--Schnellarbeitsstahl. Berlin: Diamond Business Issue 36 No. 1 (2011), pp 10.


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HSM2014–14064

REAL TIME CHATTER VIBRATION CONTROL SYSTEM IN HIGH SPEED MILLING

H. Kim1, J. Y. Koo1, M. H. Jo1, J. S. Kim2*

1PNU, FACULTY OF MECHANICAL ENGINEERING, BUSAN, REPUBLIC OF KOREA2PNU, FACULTY OF MECHANICAL ENGINEERING, ERC/NSDM, BUSAN, REPUBLIC OF KOREA


ABSTRACTThis paper presents the chatter vibration avoidance method in high speed milling. Chatter vibrations have a bad influence on surface integrity and tool life. So how to get the cutting conditions without chatter vibration is very important. In order to get stable cutting condition, too many parameters are required. So this paper focuses on simplification and real-time control of chatter avoidance program. The developed method uses only microphone

[Jung 2008] Jung, N. S. Analytical Prediction of Chatter Vibration in Milling Process, KSME mech 172–17[Merritt1965] Merritt, H. E. Analytical Prediction of Stability Lobes in Milling, Annals of CIRP, Vol. 44 No. 1, 357-362[Jianping 2006] Jianping Y. Creating a Stability Lobe Diagram, IJME Session IT 301-050[Norizanu 2010] Norizanu, S., Eiji, S. Vibration Suppressing Method And Vibra-tion Suppressing Device for Machinine Tool, US 2010/0104388 A1[Lamraoui 2014] Lamraoui, M., Thomas, M. Indicators for Monitoring Chatter In Milling Based on Instantaneous angular speeds, MSSP Vol 44, 72-85 [Sergiu 1990] Sergiu, T. Chiriacescu. Stability in the dynamics of metal cutting, ISBN 0-444-98868-8(Vol. 22)

Chatter vibration; milling; impact test; real-time control; frequency response function; LabVIEWKEYWORDS

REFERENCES

signal for chatter vibration sensing. The measuring signal is analyzed by FFT method to get whether or not the chatter vibration is generated on cutting condition. If chatter vibration occurs, the developed program suggests stable cutting spindle speed in real time with tool teeth number, damping ratio, and chatter frequency. This suggested program reliability is confirmed by dynamic cutting forces and surface profiles.

[Hiromitsu 2012] Hiromitsu, M., Toru, Y. Tracing and Visualizing Variation of Chatter for In-Process Identification of Preferred Spindle Speeds, Annals of CRIP, Vol. 4, 11–16[Norikazu 2012] Norikazu, S., Yusuke, K., Takashi, K., Rei, H., Eiji, S. Identifica-tion of transfer function by inverse analysis of self-excited chatter vibration in milling operations, Precision Engineering, Vol 36, 568-575[Altintas 2008] Altintas, Y., Eynian, M., Onozuka, H. Identification of dynamic cutting force coefficients and chatter stability with process damping, Annals of CIRP Vol. 57, No. 1, 371-374


HSM2014–14068

EXPERIMENTAL STUDY IN PLUNGE MILLING OF DAMAGE-TOLERANT TITANIUM ALLOY TC21

T. Sun1, 2, Y. Fu1*, L. He1, J. Pan1, X. Chen3, W. Zhang3, W. Chen3, X. Su3

1COLLEGE OF MECHANICAL AND ELECTRICAL ENGINEERING, UNIVERSITY OF AERONAUTICS AND ASTRONAUTICS, NANJING, CHINA2SCHOOL OF MECHANICAL AND ELECTRICAL ENGINEERING, XUZHOU INSTITUTE OF TECHNOLOGY, XUZHOU, CHINA 3CHENGDU AIRCRAFT INDUSTRY (GROUP) CO., LTD., CHENGDU, CHINA


ABSTRACTTC21 is a first self-developed high strength and damage-tolerant titanium alloy in China, which has independent intellectual property. As it is known to all, titanium alloy TC21 is widely used in many parts of aviation and aerospace fields, and the manufacture method of parts is mainly plunge milling. So in this paper, a number of experiments were carried out to study the machinability of plunge milling about TC21. Firstly, the effects of plunge milling parameters on cutting forces were investigated. Secondly, the effects of plunge milling parameters on cutting temperature were studied. Thirdly, the effects of plunge

[Yongqing Zhao 2004] Yongqing Zhao, Henglei Qu, Liang Feng, et al. Research on High Strength, High Toughness and High Damage-tolerant Titanium Alloy-TC21. TITANIUM INDUSTRY PROGRESS, February 2004, Vol. 21, No. 21, pp 22-24. ISSN 1009-9964. [Xinnan Wang 2008] Xinnan Wang, Zhishou, Zhu, Lu Tong, et al. . The Influ-ence of Forging Processing on Fatigue Crack Propagation Rate of Damage--Tolerant Titanium Alloy. Rare Metals Letters, July 2008, Vol. 27, No. 7, pp 12–16. ISSN 1008-5939. [Yuhuan Fei 2008] Yuhuan Fei, Lian Zhou, Henglei Qu, et al. . The phase and microstructure of TC21 alloy. Materials Science and Engineering: A, October 2008, Vol. 494, No. 1-2, pp 166–172. ISSN 0921-5093. [Qi Shi 2012] Qi Shi, Ning He, Liang Li, et al. . ANALYSIS 0N SURFACE IN-TEGRITY DURING HIGH SPEED MILLING FOR NEW DAMAGE-TOLERANT TITANIUM ALLOY. Transactions of Nanjing University of Aeronautics & As-tronautics, September 2012, Vol. 29, No. 3, pp 222-226. ISSN 1005–1120. [Qi Shi 2013] Qi Shi, Liang Li, Ning He, et al Experimental study in high speed milling of titanium alloy TC21. Int J Adv Manuf Technol, January 2013, Vol. 64, No. 1-4, pp 49-54. ISSN 0268-3768. [Chao Yu 2013] Chao Yu, Yan Wang, Yongjie Bao, et al. . Experimental Research on Effect of Hydrogen on Machinability of TC21 Alloy. Manufacturing Tech-nology & Machine Tool, October 2013, No. 10, pp 83-86. ISSN 1005-2402.

Damage-tolerant titanium alloy; plunge milling; cutting force; cutting temperature; tool lifeKEYWORDS

REFERENCES

milling parameters on tool life was explored. Finally, the macroscopic appearances and mechanisms of the tool breakage were analysed. Results showed that cutting force, cutting temperature, and tool life were greatly influenced by plunge milling parameters. Furthermore, the results indicated that TiAlN-coating tool was more suitable for plunge milling of TC21 than TiN-coating tool, and mechanical impact was main reason of tool breakage. Thus, cutting tool matching with proper plunge milling parameters and tool material should be carefully chosen to satisfying the tool life in actual production.

[Cheng Zhou 2013] Cheng Zhou and Haibin Li. Surface Roughness of High--Speed Milling TC21 Titanium Alloy. Aerospace Materials & Technology, December 2012, Vol. 42, No. 6, pp 105–108. ISSN 1007-2330. [Jeong Hoon Ko 2006] Jeong Hoon Ko and Yusuf Altintas. Dynamics and Stability of Plunge Milling Operations. Journal of Manufacturing Science and Engineering, July 2006, Vol. 129, No. 1, pp 32-40. ISSN 1087–1357. [Jeong Hoon Ko 2007] Jeong Hoon Ko and Yusuf Altintas. Time domain model of plunge milling operation. International Journal of Machine Tools & Manufacture, July 2007, Vol. 47, No. 9, pp 1351–1361. ISSN 0890-6955. [Ahmed Damir 2011] Ahmed Damir, Eu-Gene Ng, and Mohamed Elbestawi. Force prediction and stability analysis of plunge milling of systems with rigid and flexible workpiece. The International Journal of Advanced Manufacturing Technology, June 2011, Vol. 54, No. 9–12, pp 853-877. ISSN 0268-3768. [Shunsuke Wakaoka 2002] Shunsuke Wakaoka, Yasuo Yamane, Katsuhiko Sekiya, et al. High-speed and high-accuracy plunge cutting for vertical walls. Journal of Materials Processing Technology, September 2002, Vol. 127, No. 2, pp 246-250. ISSN 0924-0136.


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HSM2014–14088

BOTH-SIDE DRIVE OF A BALL SCREW FEED AXIS– VERIFICATION OF THE THEORETICAL ASSUMPTIONS

V. Matyska 1*



ABSTRACTA parallel run of two drives connected in synchronous position control is mainly used in feed axes of gantry machine tools in order to compensate skewing of the gantry. Other reasons for using this concept include increasing rigidity, improving dynamics or achieving thermal symmetry. In most cases these applications use separate position measuring for each drive. Therefore both drives are equivalent in terms of regulation conditions. Due to the mainly used symmetrical design of the axis, the mechanical

[Groß 2001] Groß, H., Hamann, J. and Wiegärtner, G. Electrical Feed Drives in Automation. Munich: Publics MCD Werbeagentur GmbH, 2001. ISBN 3-89578–148-7[Souček 2009] Souček, P., Novotný, L. and Rybář, P. Research of drive regu-lation of NC machine tool feed axes – Part A (in Czech). Report V-09-061. Prague: Czech Technical University in Prague, Faculty of Mechanical Engi-neering, Research Center of Manufacturing Technology, 2009.

Both-side drive; synchronous control; cascade regulation; eigen and locked-motor frequencies; eigenmodesKEYWORDS

REFERENCES

structure of drives and regulation schema connected to them are also identical. This paper aims to show the results of using two permanent magnet synchronous motors (PMSM) as two drives of the ball screw axis, which is typically and sufficiently controlled with only one drive. The following topics are discussed in this paper: changes in the mechanical structure and its dynamic behavior, effects of this concept on drive regulation and improvements in regulation parameters.

[Kitamura 2001] Kitamura, K. and Yamada, S. Drive unit for NC machine tool. Patent JP2001259953 (A). Japan: KITAMURA MACHINERY CO LTD, 2009.


INDEXA Abackerli A. J. 51

Abele E. 52Ahmad R. 36Al-Ahmari A. R. 13Ali M. A 43Andrade A. A. 51Aziz M. S. A. 43

B Bach P. 18Baizeau T. 54Bakkal M. 14, 30Barcena R. 23Barnfather J. 16Basti A. 20Bengoetxea I. 41Berglind L. 22Bergmann B. 27Beudaert X. 38Beutner M. 21Binder M. 19Bleicher F. 7Bolotskikh S. 61Bourderioux J. 54Brecher C. 45Brockmann M. 49Bruschi S. 33Bulatov O. 60Burian D. 18

C Cao H. 47Carras P. 11Cascón I. 24Cayli T. 29Coelho R. T. 51Cordes S. 28Costes J. P. 11

D D'Acunto A. 34, 35Del Conte E. G. 51Demarbaix A. 55Denkena B. 27Diatlova Ya. 61Dolimont A. 59Drobílek J. 18Ducobu F. 55Dudzinski D. 35

E Eguia J. 8Escolle B. 32Etxaniz I. 17

F Fernandez A. 8Fernández D. 41Fey M. 45Filippi E. 55, 59Florussen G. H. J. 46Fontaine M. 32, 34Frekers Y. 49Fu Y. 64

G García Navas V. 41Ghani J. A. 31Gierlings S. 49Gilbin A. 34Gossel O. 5Grove T. 27Güth S. 25Gyliene V. 15

H Ha J. Y. 9He L. 64He N. 6

Heep T. 25Heinze S. 62Hellmich A. 58Hipp K. 58Hübner F. 28

CH Che Haron C. H. 31, 43Chen W. 64Chen X. 47, 64Cho M. H. 57Chvojka P. 18

I Ihlenfeldt S. 44Iturbe I. 17

J Jedrzejewski J. 9Jo M. H. 63

K Kalocsay R. 50Karpuschewski B. 21Kasim M. S. 31, 43Kawano Y. 56Keitzel G. 48Kim H. 57, 63Kim J. S. 57, 63Klocke F. 12, 19, 29, 48, 49Kneer R. 49Köchig M. 21Kondo E. 56Koo J. Y. 57, 63Korableva N. 60Kovelenov N. 60, 61Krall S. 7Kuznetsova I. 60Kuzu A. T. 14, 30

L Lacharnay V. 37Landon Y. 42Lavernhe S. 37,38Law M. 44Lee Ch. H. 39Lechner C. 7Leong A. 25Leyens C. 62Li L. 6Li Y. 47Loehe J. 4Lorong P. 11Lung D. 12, 19, 29

M Malý J. 26Mancisidor I. 23Matyska V. 65Mikhailov S. 61Mohamad E. 31Morel M. A. A. 46Moussaoui K. 42Munoa J. 17Musfirah A. H. 43

N Neugebauer R. 58O Obermair M. 7

Obikawa T. 20Ottersbach M. 50

P Pan J. 64Petit F. 55Picart P. 32Piquard R. 34, 35Plapper P. 36Poláček M. 18Ponomarenko V. 60Poulachon G. 11

Preux N. 55Puls H. 12

Q Qudeiri J. A. 13R Rahimzadeh Berenji K. 14, 30

Rahman M. N. A 43Rehe M. 27Rey P. A . 42Richterich C. 10Rivière-Lorphèvre E. 55, 59Rysava Z. 33

S Sadik M. I. 40Saillard J. 54Sandá A. 41Sarasua J. A. 24Selmi J. 11Senatore J. 42Shi J. 39Shimana K. 56Shinozuka J. 20Schaarschmidt T. 28Schäfer A. 10Schlegel H. 58Schmidt S. 52Schützer K. 51Spaan H. A. M. 46Stawiszynski B. 62Stolorz M. 50Su X. 64Sulaiman M. A. 31Sulitka M. 10Sun T. 64

Š Šindler J. 10T Tanabe I. 53

Thibaud S. 32, 34Tournier C. 37, 38Tristo G. 33Tunc L. T. 16

U Ubartas M. 15Uhlmann E. 62Umer U. 13Uriarte L. 8, 17Ur-Rehman R. 10

V Veselovac D. 48, 49Vogtel P. 19

W Wabner M. 44Wagner M. 45Wang Y. 39Wengler M. 21Winiarski Z. 9

Y Yamashita S. 56Yan Ch. 39Yang J. 39Yang Y. 6Ye D. H. 57Yoshidome A. 56Yusuff A. M. 13

Z Zäh M. F. 4Zatarain M. 17Zeman P. 26Zhang W. 64Zhang X. 47Zhao W. 6Ziegert J. 22


COMMITTEES OF HSM 2014

International Scientific CommitteeProf. Eberhard Abele, GermanyProf. Yusuf Altintas, CanadaDr. Ana Aranzabe, SpainProf. Pedro-José Arrazola, SpainAssoc. Prof. Petr Blecha, Czech RepublicProf. Friedrich Bleicher, AustriaProf. Christian Brecher, GermanyProf. Erhan Budak, TurkeyProf. Alain D´Acunto, FranceProf. Matthew A. Davies, USAProf. Berend Denkena, GermanyProf. Piotr Dudzinski, FranceProf. Kaan Erkorkmaz, CanadaProf. Wit Grzesik, PolandProf. Ning He, ChinaProf. Wolfgang Hintze, GermanyDr. Steffen Ihlenfeld, GermanyProf. Jerzy Jedrzejewski, PolskoProf. Chengyu Jiang, ChinaProf. Ismail Lazoglu, TurkeyProf. Jürgen Leopold, ChinaDr. Christophe Lescalier, FranceDr. Kai Litwinski, GermanyDr. Rachid M´Saoubi, SwedenProf. Hans-Christian Möhring, GermanyDr. Jokin Munoa, SpainProf. Piotr Nieslony, PolandProf. Tuğrul Özel, USAAssist. Prof. Franci Pušavec, SloveniaDr. Matthieu Rauch, FranceProf. Scott Smith, USAProf. Gábór Stépán, HungaryDr. Luis Uriarte, SpainProf. Michael Zäh, GermanyDr. Mikel Zatarain, SpainDr. Pavel Zeman, Czech Republic

ChairmanDr. Petr Kolář | Research Center of Manufacturing Technology, Faculty of Mechanical Engineering, Czech Technical University in Prague Co-chairmenDr. Jan Smolík | Research Center of Manufacturing Technology, Faculty of Mechanical Engineering, Czech Technical University in PragueDr. Matěj Sulitka | Research Center of Manufacturing Technology, Faculty of Mechanical Engineering, Czech Technical University in Prague

Keynote speakersProf. Friedrich Bleicher, AustriaDr. Oliver Gossel, GermanyProf. Ning He, China Prof. Michael Zaeh, Germany

Session ChairmenProf. Eberhard AbeleProf. Friedrich BleicherProf. Alain D'AcuntoProf. Ning HeProf. Jerzy JedrzejewskiProf. Chengyu JiangDr. Petr KolářDr. Jokin MunoaProf. Piotr NiesłonyProf. Tuğrul ÖzelDr. Matěj SulitkaProf. Michael ZähDr. Pavel Zeman

Conference OfficeZuzana Čejková

Local Organizing TeamMarie ČapkováZuzana ČejkováTereza DobešováAlena LiškováJana Rudyšová

Local Technical SupportJan BrajerJaroslav ČervenkaJosef KekulaJan VláčilTomáš Zavázal


Modern Machinery Science Journal is:• world respected scientific journal• published since 2008 in English• double peer reviewed • open access• indexed in Scopus

Focused on:• engineering design theory, methodology and creativity• inovations in engineering design of production machines• automation and mechatronics, including robots and related technologies

www.mmscience.eu – presents the results of scientific work

MM Science Journal is indexed in Scopus database!

al is:

odology andd creativity

Special offer for

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Publish your Paper

for a discount price

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The Czech Technical University in Prague Faculty of Mechanical Engineering

Research Center of Manufacturing Technology

Technische Universität Darmstadt The Institute of Production Management,

Technology and Machine Tools

The Czech Technical University in Prague

Ecole Nationale Supérieure d´Arts et Métiers

Nanjing University of Aeronautics and Astronautics

IK4 TeknikerCzech Machine Tool Society

Sponsored by the International Academy for Production Engineering CIRP

11TH INTERNATIONAL CONFERENCE

ADVANCES IN MANUFACTURING TECHNOLOGY

BOOK OF ABSTRACTS

Book of Abstracts Paper Fulltexts

Acknowledgements | Organizers and Partners

Czech Machine Tool Society | CMTSHorská 3, 128 Prague 2, Czech RepublicPhone | +420 221 990 940, Email | [email protected]

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