A Study on Improving the Machining Performance of Scrolls

Abstract

To improve machining efficiency and product precision in scroll manufacturing, we studied three adaptive milling processes: adaptive feed rate planning, chatter suppression measures, and optimization of milling parameters during the rough, semi-fine, and fine machining of scrolls. In the rough machining of scrolls, adaptive feed rate planning was used to compute the cutting area per cutter tooth in real time in order to adjust the feed rate and optimize the material removal rate (MRR) under a given maximum acceptable cutting load. To suppress the possibility of chatter in the semi-fine and fine machining processes, the chatter frequencies were detected with a microphone and the spindle speeds were promptly modified using a developed program in combination with the controller of the milling machine. Based on the Taguchi method and analysis of variance (ANOVA), we determined the optimum milling parameters for the fine machining processes to improve contour characteristics, such as the profile errors and surface roughness of scrolls. Experimental tests were implemented to demonstrate and verify the feasibility of the adaptive milling processes proposed in this study.