Abstract: Many orthopedic implants like proximal humerus cases require lower surface roughness and almost immediate/short lead time surgery. Thus, rapid response from the manufacturer is very crucial. Tool path strategy of milling process has a direct influence on the surface roughness and lead time of medical implant. High-speed milling as promised process would improve the machined surface quality, but conventional or super-abrasive grinding still required which imposes some drawbacks such as additional costs and time. Currently, many CAD/CAM software offers some different tool path strategies to milling free form surfaces. Nevertheless, the users must identify how to choose the strategies according to cutting tool geometry, geometry complexity, and their effects on the machined surface. This study investigates the effect of different tool path strategies for milling a proximal humerus head during finishing operation on stainless steel 316L. Experiments have been performed using MAHO MH700 S vertical milling machine and four machining strategies, namely, spiral outward, spiral inward, and radial as well as zig-zag. In all cases, the obtained surfaces were analyzed in terms of roughness and dimension accuracy compared with those obtained by simulation. The findings provide evidence that surface roughness, dimensional accuracy, and machining time have been affected by the considered tool path strategy.
Abstract: Chatter vibration has been a troublesome problem
for a machine tool toward the high precision and high speed machining.
Essentially, the machining performance is determined by the dynamic
characteristics of the machine tool structure and dynamics of cutting
process, which can further be identified in terms of the stability lobe
diagram. Therefore, realization on the machine tool dynamic behavior
can help to enhance the cutting stability. To assess the dynamic
characteristics and machining stability of a vertical milling system
under the influence of a linear guide, this study developed a finite
element model integrated the modeling of linear components with the
implementation of contact stiffness at the rolling interface. Both the
finite element simulations and experimental measurements reveal that
the linear guide with different preload greatly affects the vibration
behavior and milling stability of the vertical column spindle head
system, which also clearly indicate that the predictions of the
machining stability agree well with the cutting tests. It is believed that
the proposed model can be successfully applied to evaluate the
dynamics performance of machine tool systems of various
configurations.
Abstract: The machining performance is determined by the
frequency characteristics of the machine-tool structure and the
dynamics of the cutting process. Therefore, the prediction of dynamic
vibration behavior of spindle tool system is of great importance for the
design of a machine tool capable of high-precision and high-speed
machining. The aim of this study is to develop a finite element model
to predict the dynamic characteristics of milling machine tool and
hence evaluate the influence of the preload of the spindle bearings. To
this purpose, a three dimensional spindle bearing model of a high
speed engraving spindle tool was created. In this model, the rolling
interfaces with contact stiffness defined by Harris model were used to
simulate the spindle bearing components. Then a full finite element
model of a vertical milling machine was established by coupling the
spindle tool unit with the machine frame structure. Using this model,
the vibration mode that had a dominant influence on the dynamic
stiffness was determined. The results of the finite element simulations
reveal that spindle bearing with different preloads greatly affect the
dynamic behavior of the spindle tool unit and hence the dynamic
responses of the vertical column milling system. These results were
validated by performing vibration on the individual spindle tool unit
and the milling machine prototype, respectively. We conclude that
preload of the spindle bearings is an important component affecting
the dynamic characteristics and machining performance of the entire
vertical column structure of the milling machine.