Abstract: One of the main research directions in CAD/CAM
machining area is the reducing of machining time.
The feedrate scheduling is one of the advanced techniques that
allows keeping constant the uncut chip area and as sequel to keep
constant the main cutting force. They are two main ways for feedrate
optimization. The first consists in the cutting force monitoring, which
presumes to use complex equipment for the force measurement and
after this, to set the feedrate regarding the cutting force variation. The
second way is to optimize the feedrate by keeping constant the
material removal rate regarding the cutting conditions.
In this paper there is proposed a new approach using an extended
database that replaces the system model.
The feedrate scheduling is determined based on the identification
of the reconfigurable machine tool, and the feed value determination
regarding the uncut chip section area, the contact length between tool
and blank and also regarding the geometrical roughness.
The first stage consists in the blank and tool monitoring for the
determination of actual profiles. The next stage is the determination
of programmed tool path that allows obtaining the piece target
profile.
The graphic representation environment models the tool and blank
regions and, after this, the tool model is positioned regarding the
blank model according to the programmed tool path. For each of
these positions the geometrical roughness value, the uncut chip area
and the contact length between tool and blank are calculated. Each of
these parameters are compared with the admissible values and
according to the result the feed value is established.
We can consider that this approach has the following advantages:
in case of complex cutting processes the prediction of cutting force is
possible; there is considered the real cutting profile which has
deviations from the theoretical profile; the blank-tool contact length
limitation is possible; it is possible to correct the programmed tool
path so that the target profile can be obtained.
Applying this method, there are obtained data sets which allow the
feedrate scheduling so that the uncut chip area is constant and, as a
result, the cutting force is constant, which allows to use more
efficiently the machine tool and to obtain the reduction of machining
time.
Abstract: Tool wear and surface roughness prediction plays a
significant role in machining industry for proper planning and control
of machining parameters and optimization of cutting conditions. This
paper deals with developing an artificial neural network (ANN)
model as a function of cutting parameters in turning steel under
minimum quantity lubrication (MQL). A feed-forward
backpropagation network with twenty five hidden neurons has been
selected as the optimum network. The co-efficient of determination
(R2) between model predictions and experimental values are 0.9915,
0.9906, 0.9761 and 0.9627 in terms of VB, VM, VS and Ra
respectively. The results imply that the model can be used easily to
forecast tool wear and surface roughness in response to cutting
parameters.
Abstract: This paper presents a experiment to estimate the
influences of cutting conditions in microstructure changes of
machining austenitic 304 stainless steel, especially for wear insert. The
wear insert were prefabricated with a width of 0.5 mm. And the forces,
temperature distribution, RS, and microstructure changes were
measured by force dynamometer, infrared thermal camera, X-ray
diffraction, XRD, SEM, respectively. The results told that the different
combinations of machining condition have a significant influence on
machined surface microstructure changes. In addition to that, the
ANOVA and AOMwere used to tell the different influences of cutting
speed, feed rate, and wear insert.
Abstract: In this paper by measuring the cutting forces the effect
of the tool shape and qualifications (sharp and worn cutting tools of
both vee and knife edge profile) and cutting conditions (depth of cut
and cutting speed) in the turning operation on the tool deflection and
cutting force is investigated. The workpiece material was mild steel
and the cutting tool was made of high speed steel. Cutting forces
were measured by a dynamometer (type P.E.I. serial No 154). The
dynamometer essentially consisted of a cantilever structure which
held the cutting tool. Deflection of the cantilever was measured by an
L.V.D.T (Mercer 122) deflection indicator. No cutting fluid was used
during the turning operations. A modern CNC lathe machine (Okuma
LH35-N) was used for the tests. It was noted that worn vee profile
tools tended to produce a greater increase in the vertical force
component than the axial component, whereas knife tools tended to
show a more pronounced increase in the axial component.