Journal ArticleDOI
Feed rate optimization based on cutting force calculations in 3-axis milling of dies and molds with sculptured surfaces
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TLDR
In this article, the authors developed a method for estimating the cutting forces in 3-axis milling so that the NC programmer can "optimize" the machining parameters and establish the best rough milling strategy to reduce machining time and cost.Abstract:
The use of CAD/CAM systems and NC machine tools for die and mold manufacturing offers considerable advantages over conventional methods, such as reduction in machining time and costs, and improvements in accuracy and reproducibility. However, the selection of cutting tools and machining strategy and parameters, which have a significant impact on overall machining efficiency and process reliability, still depends on the experience of the machinist or the NC programmer. Based on these considerations, this study had two major objectives: (a) develop a method for estimating the cutting forces in 3-axis milling so that the NC programmer can “optimize” the machining parameters; and (b) establish the “best” rough milling strategy to reduce machining time and cost. This paper concentrates on the first objective, namely on optimizing the feed rate to improve machining efficiency in end milling. By simulating the end milling process and predicting the cutting force in 3-axis milling of sculptured surfaces, an approach and the associated computer program have been developed to optimize the feed rate, already at the NC programming stage. The calculated cutting force, which includes the overall net effect of all process variables, is used as a feedback variable to adjust the feed rate. The method also allows the NC programmer to visualize cutting forces in a CATIA CAD/CAM environment.read more
Citations
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Journal ArticleDOI
Manufacturing of Dies and Molds
TL;DR: The design and manufacturing of dies and molds represent a significant link in the entire production chain because nearly all mass produced discrete parts are formed using production processes that employ dies and mold as mentioned in this paper.
Journal ArticleDOI
NC end milling optimization using evolutionary computation
TL;DR: A new evolutionary computation technique, particle swarm optimization (PSO), is proposed and implemented to efficiently and robustly optimize multiple machining parameters simultaneously for the case of milling.
Journal ArticleDOI
Sculpture surface machining: a generalized model of ball-end milling force system
TL;DR: In this paper, a new mechanistic model is presented for the prediction of a cutting force system in ball-end milling of sculpture surfaces, which has the ability to calculate the workpiece/cutter intersection domain automatically for a given cutter location (CL) file, cutter and workpiece geometries.
Journal ArticleDOI
On the optimization of machining parameters for milling operations
Majid Tolouei-Rad,I.M. Bidhendi +1 more
TL;DR: In this paper, the authors present an optimization system which determines the optimum machining parameters for milling operations, which are intended for use by NC machines, however, they can also be used by conventional machines.
Journal ArticleDOI
Structural modeling of end mills for form error and stability analysis
Evren Burcu Kivanc,Erhan Budak +1 more
TL;DR: In this article, the static and dynamic analysis of milling tools with different geometry and material are carried out by finite element analysis (FEA) and some practical equations are developed to predict the static or dynamic properties of tools.
References
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Journal ArticleDOI
An Overview of Modeling and Simulation of the Milling Process
Scott R. Smith,J. Tlusty +1 more
Journal ArticleDOI
End Milling Force Algorithms for CAD Systems
TL;DR: In this article, a tool-workpiece interaction is represented using immersion segments obtained by intersecting the cutter with each part feature, and a cutting mechanics model is used to predict the instantaneous, average and peak forces, and maximum cutter deflections left on the finished part surface.
Journal ArticleDOI
A Cutting Simulation System for Machinability Evaluation Using a Workpiece Model
TL;DR: In this article, a cutting simulation system is described to evaluate machinability of products at various stages of the manufacturing process, which is performed by using extended Z buffer models representing a workpiece and a tool swept volume.
Journal ArticleDOI
Determination of the Values of the Technological Parameters which are Used to Describe the Time Course of Cutting Force Components in Milling
TL;DR: In this paper, a computer-supported evaluation method of cutting force components measurments is developed, which regards the measured time course of the cutting force and will be demonstrated in the case of milling.
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