CNC Milling Machine Research Articles

An Evaluation of Some Specifications of Turbine Blades Made by 3D Printing and Machining on CNC Milling Machines

This paper presents the research results on manufacturing turbine blades in turbocharger machined on Haas VF2 module TRT 160 5-axis CNC milling machine and by 3D printing method on Metal 3D printer HBD-280 series with the same material AlSi10Mg. The research sample is the compressed turbine blades in the HX40W turbocharger mechanism. CAD data files for machining programming and 3D printing of turbine blades are scanned from an ATOS Core 80 scanner with GOM and Geomagic Design X softwares. Some specifications of the two manufacturing methods are also presented. Research results show that the error of average diameter and surface roughness of 3D printing method is larger than that of machining on a CNC milling machine.

Refractive Bi-Conic Axicon (Volcone) for Polarization Conversion of Monochromatic Radiation

A new element is proposed for producing an azimuthally polarized beam with a vortex phase dependence. The element is formed by two conical surfaces in such a way that the optical element resembles a mountain with a crater on top, like a volcano (volcanic cone is volcone). The element in the form of a refractive bi-conic axicon is fabricated by diamond turning, in which an internal conical cavity is made. Polarization conversion in this optical element occurs on the inner surface due to the refraction of beams at the Brewster angle. The outer surface is used to collimate the converted beam, which significantly distinguishes the proposed element from previously proposed approaches. The paper describes a method for calculating the path of beams through a refractive bi-conic axicon, taking into account phase and polarization conversions. In the case of incident circularly polarized radiation, azimuthally polarized ring-shape beam radiation is generated at the output. The proposed element is experimentally made of polymethyl methacrylate on a CNC milling machine. The experiment demonstrates the effectiveness of the proposed element.

Modelling and Analysis of CNC Milling Machine Bed with UHM CFRP composite Material

Abstract: Structural materials are used in a machine tool have a key role in defining the productivity, accuracy and Size proportions of the part manufactured by machine tool. The conventional structural materials like cast iron and Stainless or carbon steel at high operating speeds but used in precision machine tools grow positional errors due to the vibrations transferred into the Machine tool structure. Faster cutting speeds can be achieve only by structure which has good damping characteristics and high stiffness. Clearly the life of a machine tool is proportional to the levels of vibration Produce by machine. The further Work is carried out to Study the deformation and natural frequency using Static analysis and Modal analysis respectively. The bed in machine tool Took Major role in the precision in components. It is one of the greatest vital tool structures which is absorb the vibrations resultant from the cutting operation. To analyse the bed for possible material changes and Structure changes that could increase stiffness, decrease weight, expand damping characteristics and segregate natural frequency at the operating range. So main enthusiasm behind the impression to go for a composite Material in model involving ultra-High Modulus Carbon Fibre Reinforced Polymer Composite Material (UHM CFRP). In a carbon has good stiffness and strength properties but its absences in damping requirements. On the other hand, polymers, though its deficiencies in strength but, good damping in characteristics and it is easily holding the carbon fibres. So, this is makes greatest combination of materials in an appropriate manner. In this work, a machine tool’s bed is selected for the analysis static loads. Then study is carried out to decrease the weight of the machine tool’s bed without affecting its structural rigidity. The 3D CAD model of the bed has been created by using commercial 3D modelling software and analyses were carried out using ANSYS 2021 R2. Keywords: Composite material, hybrid structures, Milling machine bed, UHM CFRP.

Mechanical properties and machinability of lithium silicate glass-ceramics with varying MgO content

This study focused on the role of lithium metasilicate crystalline phase and microstructural evolution on altering the mechanical properties and machinability of two glass-ceramic system, (Li2O–K2O–Na2O–CaO–MgO–ZrO2–Al2O3–P2O5–SiO2), previously developed by our research group. Our previous study showed that increasing MgO content introduced phase separation and thus controlling the crystallization and microstructure of the glass-ceramics. For this study we chose the glass ceramic system with 1.5 and 4.5 mol% MgO. The glass-ceramics were prepared by melt cast method followed by heat treatment at 650 °C to induce partial crystallization. The crystalline phase in the glass-ceramics was identified by x-ray diffraction and the quantification of crystalline and amorphous phase content was done using Rietveld refinement. The hardness and elastic moduli were measured by nanoindentation. Vickers hardness and fracture toughness were determined by micro indentation. Nano scratch test was performed and scratch morphology was characterized using AFM and FEG-SEM. In order to compare the machinability of the prepared glass-ceramic samples, milling experiments were carried out using CNC milling machine, and machining characteristics were compared by analysing machining force, surface roughness and microstructure of the machined surface. Presence of higher amount of lithium metasilicate (LS) crystals in higher magnesia containing glass-ceramic (G2) resulted in lower average force (Fyrms) as compared to lower MgO containing glass-ceramic. However, due to a wide range of variation in crystal size (150 nm - 2 μm) in higher MgO containing glass-ceramic, the force fluctuation was more than lower MgO containing glass-ceramics.

Desain dan Pembuatan Mesin CNC Milling untuk Pembuatan Ukiran Kerajinan Kayu

<p>The furniture industry is an industry that processes raw materials or semi-finished materials from wood, rattan and other natural raw materials into finished products that are ready for use and have higher added value. There are many furniture industries spread across Indonesia, with quite large centers located in Jepara, Sukoharjo, Surakarta, Klaten, and others. Along with the development of industrial technology, making work becomes more efficient and easier. Therefore, it is necessary to apply technology in the industrial world in Indonesia, especially in the furniture industry. The current technology commonly applied to the furniture industry is the CNC milling machine. The use of this CNC machine aims to solve problems in the production of wood carving crafts or furniture, such as mass products that cannot be the same and product processing time that cannot be ascertained. Besides, the use of this CNC machine can reduce cycle times and increase the work efficiency of the furniture industry. Based on this information, we had the idea to make this CNC milling machine to support the progress of the Indonesian furniture industry. During the manufacturing of this CNC machine, we carried out theoretical research and field surveys. The research stages we carried out were identification of needs, problem formulation, synthesis, analysis, evaluation and presentation. Based on these results, it was found that the workable raw material had a maximum dimension of 40 × 40 [cm], a maximum feed rate of 192 [mm/min], a maximum spindle rotating speed of 12,000 [rpm] and a cutting velocity of 75.4 [m/min].</p>

Reverse Engineering Algorithm for Cutting of Ruled Geometries by Wire

Abrasive wire cutting (AWC) and wire electric discharge machining (WEDM) are efficient and economical processes for the fabrication of precision parts from bulk material. Operating costs and manufacturing lead times are low compared to more general methods such as 5-axis CNC milling, turning, or electro-discharge machining. In this paper, an algorithm based on differential geometry in Euclidean space is proposed for reverse engineering of ruled geometries. The algorithm can determine whether a given geometry is producible by wire cutting, and can also derive the associated wire trajectories. Implementation is demonstrated by producing complex turbine blade geometries on 4-axis wire cutting machines with an overall shape accuracy of 20–40 μm peak-to-valley.

REDUCING SOUND INTENSITY BY OPTIMIZING CUTTING PARAMETERS ON CNC MILLING MACHINES

In the cutting process with machine tools in the Machinery Manufacturing Industry; while the desired surface integrity is ensured by the optimization of the cutting parameters, the noise level must be kept at a minimum to protect the health of the workers. The noise level can be reduced by using this optimization without compromising the surface roughness through processing of EN AW 6013 material on a CNC milling machine. Experimental design was examined in three variables, three levels and two target functions. The effects of these parameters on the target function were studied by performing experimental plans determined by "Central Composite Design (CCT)" of Response Surface Method (RSM)". To assess the sound intensity and surface roughness, mathematical models were developed by performing regression analysis on the experimental results. These developed models have been tested with control experiments and it has been seen that the models have acceptable error rates. The obtained regression equation is highly modeled with a validity of 93.29% for sound intensity and 97.33% for surface roughness. Therefore, cutting parameters were found to be related to sound intensity and surface roughness values.

Effect of Machining Condition on Surface Roughness and Hardness in Milling of AA6061 Aluminium Alloy

Roughness of a machined surface should be as par the customer requirement to suite a particular application. For achieving the desired surface finish, appropriate values of cutting velocity, feed and depth of cut are to set, and these can be found out utilizing an optimization technique. In this study, the machining process is executed on AA6061 aluminium alloy by appling cutting fluid in a CNC milling machine and then roughness of surface and hardness are measured by a surface roughness tester and Brinell hardness tester respectively.

Research on the Recognition of Machining Conditions Based on Sound and Vibration Signals of a CNC Milling Machine

Machining conditions of real-time identification tools is a key and trending issue for the industry. This paper focuses on identifying whether machining is performed as well as the chatter conditions generated during re-machining processes. Identifying whether or not machining conditions are met allows users to ensure the normal operation of machining equipment and identify situations that do not match the current conditional, so that they can take early action and further save on operational costs for machining. The objective of this paper is to identify the milling machining conditions, and the identified conditions will be categorized into whether cutting is required as well as whether chatter is observed. In order to identify these three conditions, sound and vibration signals are captured by sensors inside the milling machine, and the process of identification is subsequently analyzed and conditions established. In this paper, in order to produce a valid model, the extracted machining signal is characterized as a training model by the properties of Approximate Entropy and Short-Time Fourier Transform, and the k-fold cross-validation criteria is utilized to present the identification results. Finally, In this study, the model recognition rate of support vector machine with approximate entropy was 91.4%. The recognition rate of the convolutional neural network with short time span Fourier transform was 95.5%. Finally, the reduced network architecture can significantly reduce the training time and maintain the recognition rate at 93.6%.

Comparative analysis between co-curing and adhesive bonding of glass-epoxy composite laminates and AA5083 aluminium sheets for Maritime application: effect of surface pattern

Co-curing and secondary bonding are effective techniques to join not only composite structures but also dissimilar materials such as metals and composites whose combined use is increasing in several industrials fields where lightness is strategic to reduce fuel consumption and, consequently, greenhouse emissions (i.e. transports). In particular, the aim of this research is to investigate the effect of different patterns both on co-cured glass-epoxy composite/aluminium joints and on the same joints made with adhesive as third material to bond the aluminium and the laminate preliminary realized by vacuum infusion. These configurations and the materials to join were used typically in maritime applications, i.e. the composite can be used for the main deck and the aluminium for the superstructures. The patterns were made with a controlled milling machine equipped with an engraver with a 45° cutting angle. In both cases, the results showed that the mechanical treatment affected the mechanical properties, i.e. the joint with the best pattern had a higher mechanical strength than the joint where the surface was not treated. Moreover, this influence was more significant for co-curing. Finally, a statistical analysis was performed to evaluate the significance of both the selected factors: i.e. joining process and treatment, and their interaction. The novelty of the work lay both in the materials used to make the joints, which are employed in marine applications, in the use of macroscopic pattern to treat the metal surface for co-cured joints, and in the manufacturing process, which used a CNC milling machine.

Method for Enhanced Accuracy in Machining Free-Form Surfaces on CNC Milling Machines

Abstract The present article describes a method for enhanced accuracy in machining free-form surfaces produced on CNC milling machines. In this method, surface patch machining programs are generated based on their nominal CAD model. After the pretreatment, coordinate control measurements are carried out. The obtained results of the measurements contain information on the values and distribution of observed machining deviations. These data, after appropriate processing, are used to build a corrected CAD model of the surface produced. This model, made using reverse engineering techniques, compensates for the observed machining deviations. After regeneration of machining programs, the object processing and control measurements are repeated. As a result of the conducted procedure, the accuracy of the manufacture of the surface object is increased. This article also proposes the introduction of a simple procedure for the filtration of measurement data. Its purpose is to minimise the effect of random phenomena on the final machining error correction. The final part of the article presents the effects of the proposed method of increasing the accuracy of manufacturing on ‘raw’ and filtered measurement data. In both cases, a significant improvement in the accuracy of the machining process was achieved, with better final results obtained from the filtered measurement data. The method proposed in the article has been verified for three-axis machining with a ball-end cutter.

A Data Warehouse-Based System for Service Customization Recommendations in Product-Service Systems.

Nowadays, manufacturers are shifting from a traditional product-centric business paradigm to a service-centric one by offering products that are accompanied by services, which is known as Product-Service Systems (PSSs). PSS customization entails configuring products with varying degrees of differentiation to meet the needs of various customers. This is combined with service customization, in which configured products are expanded by customers to include smart IoT devices (e.g., sensors) to improve product usage and facilitate the transition to smart connected products. The concept of PSS customization is gaining significant interest; however, there are still numerous challenges that must be addressed when designing and offering customized PSSs, such as choosing the optimum types of sensors to install on products and their adequate locations during the service customization process. In this paper, we propose a data warehouse-based recommender system that collects and analyzes large volumes of product usage data from similar products to the product that the customer needs to customize by adding IoT smart devices. The analysis of these data helps in identifying the most critical parts with the highest number of incidents and the causes of those incidents. As a result, sensor types are determined and recommended to the customer based on the causes of these incidents. The utility and applicability of the proposed RS have been demonstrated through its application in a case study that considers the rotary spindle units of a CNC milling machine.

Development and Design of a Machine Using Standard Aluminium Profiles

The goal of this research is development, design and manufacturing of CNC milling machine prototype using standard aluminium profiles. Machine is a three axis’s machine and it is developed primarily for education in the field of wood machining. It can be used also for machining of light metal parts. Main initial goal of the machine development was the low cost for its manufacturing. To achieve this goal, rapid prototyping technology was used to manufacture most of the machine parts. In addition, a lot of standard parts are used. The detail methodology for machine development, design and manufacturing are shown in this paper. Design process includes development of CAD models, calculation of all necessary critical parts, selections of materials and development of machine subassemblies and assemblies.

Effect of Machining Parameters on Cutting Performance of DSS 2205 and SDSS 2507 Materials During Milling Operation

Duplex and super duplex materials have properties of both austenite and martensitic steels. Properties like hardness and toughness are very high for duplex grades, and it is difficult to machine. In this study, machining performance of DSS 2205 and SDSS 2507 was estimated during dry milling operation using CNC milling machine. The impact of feed rate, spindle speed and depth of cut on cutting force and surface roughness was estimated using 16 run experiments. Four levels of spindle speeds ranging from 1400 to 5600[Formula: see text]rpm, feed rate ranging from 50 to 200[Formula: see text]mm/min and depth of cut ranging from 0.35 to 1.40[Formula: see text]mm were considered for the experiment. Contour plots generated using Minitab 18 revealed that level of spindle speed, feed rate and depth of cut should be maintained at lower levels for achieving minimum cutting force. In order to achieve minimum surface roughness, lower levels of feed rate with moderate speed and lower depth of cut are to be preferred for both materials. While analyzing cutting force and surface roughness values, it was found that machinability of DSS 2205 was better than SDSS 2507 due to lower wt.% of chromium, molybdenum and nickel in DSS 2205 compared to SDSS 2507 material.

Autonomous self-healing mechanism for a CNC milling machine based on pattern recognition

Autonomous self-healing mechanism for a CNC milling machine based on pattern recognition

Development and Application of Educational Mini CNC Milling Machines

Industrial CNC milling machine is huge in volume, complex in structure, poor in system openness and expensive in price, which increases the cost of training relevant professional and technical personnel in enterprises and schools, and restricts the further development of CNC milling machine. In order to solve this problem, based on the existing domestic CNC milling machine and previous research results, this paper designs a teaching type micro CNC milling machine with high integration, low cost, convenient handling, simple structure and high flexibility, and carries out processing experiments on the micro CNC milling machine. The experimental results show that when the spindle speed is 5000 r/min, the feed rate is 2000 mm/min and the engraving cutter is 1 mm, the machining error of the teaching type micro CNC milling machine is 0.1 ~ 0.2 mm, can well reflect the shape of the object to be processed, can meet the students' understanding and learning of CNC machine tools, and meet the needs of carving enthusiasts, in order to make contributions to the further development of CNC milling machines in China.

Optimization of cutting parameters during CNC milling of EN24 steel with Tungsten carbide coated inserts: A critical review

Recent developments in advanced technology have led to CNC milling machines in many industries to achieve better quality and productivity. The CNC milling machine outperforms traditional machines in precision and surface quality. By optimizing the process parameters, one can fully utilize CNC milling machining. As a result, this paper reviews the optimizing process parameters for CNC milling using Tungsten coated carbide tools. The review shows that the feed, speed, and DOC influence material removal rate, surface roughness, and tool wear. researchers have used Taguchi and RSM for Optimization. Surface and contour graphs to analyze the effect of milling parameters on tool wear, MRR, and surface roughness. For optimization, the response surface methodology (RSM) by approach. The impact of machining parameters on response parameters is analyzed using ANOVA. It was found that there is scope for optimizing the process parameters for the material EN24.

Development of Al-SiC composite material from rice husk and its parametric assessment

In this research work, the development of Al-SiC composite material from rice husk and its parametric assessment is done using a CNC milling machine. They are further surface characterized, and mechanical properties such as BET surface area, SEM-EDX, and XRD, fracture toughness, tensile, and bending strength are studied. The machinability of the components is investigated for selected values of input-output parameters. Three castings, each with different particulate reinforcement combinations, are made with aluminum alloy (6061) using the stir casting method. BET surface area of extracted silica and Al-SiC composite material was found 374 m2 g−1 and 150 m2 g−1, respectively. From results of BET surface area revealed that silica obtained from rice husk is more heterogeneous with a large surface area. A heterogeneous surface with larger pores was found through SEM images. XRD diffraction peaks show changes of amorphous silica into crystallinity in the composite material. The results also indicate that fracture toughness is very good at low temperatures and good machinability on CNC milling machines makes it suitable for aerospace applications.

Fuzzy logic modelling in drilling operation

In this research, work various machining parameters can be analyzed with the help of fuzzy logic model. In industry, mostly drilling machines will be used for making various types of holes. It has its importance because of its complexity and economic in nature. In drilling operation various machining parameters like spindle speed, feed rate, depth of cut analyzed with help of Design of experiments (DOE) concept along with the fuzzy logic. CNC Milling machine is used to perform drilling operation on phosphor bronze plate of dimensions 98 mm × 98 mm × 8 mm. Speed of Spindle(SS), depth of cut(DOC) and feed rate(FR) are the selected machining parameters and the responses are Surface roughness(SR), Material removal rate(MRR). Fuzzy logic model is developed based on universe portioning, rules formation, rules combination, fuzzy relation and relationship between input and output membership function. As an experimental result, it is known that high MRR will occurs when increasing of SS and DOC.SR increases with rise in speed and cutting depth. The predicted value using fuzzy logic is close enough to experimental value.

Multi-Criteria ranking algorithm for high quality of products in high performance drilling Operation: A case study for considering the Wide-Web and Cryo treated drills

Among the most commonly used tools in the industrial business, high-speed steel (HSS) tools rank first. A large web thickness and cryogenic treatment were used to obtain the most significant improvements in machining quality with the HSS tool. The results of this study are presented in this publication. Being stiffer in nature than normal drills, they have always had the ability to drill straighter, deeper, and more exact hole diameters than standard drills. Furthermore, wide-web drills often allow for feed rates that are approximately 20% faster than standard drills, and the strength of a wide belt makes it the ideal tool for deep cuts in hard materials. On the basis of a multi-criteria classification technique, this study discusses how to select the appropriate process parameter to obtain the highest possible level of drilling quality. These findings concern the optimization of drilling settings utilising a strategy to get the lowest possible deviation from cylindricity, surface roughness (Ra), roundness error, and burr. Cylindricity, surface roughness (Ra), roundness error, and burr are all considered in this study. Mistreating the L9 orthogonal die on the CNC milling machine resulted in a series of drilling trials, which were then recorded. The traces were made on the ZE41 block, which was produced by gravity die casting, with a cutting tool of a 4 mm diameter treated HSS drill, which was employed during experimental work in dry cutting circumstances to make the traces. The Combinative Distance-based ASsessment (CODAS) and ANOVA were used to determine the main spindle speed, feed rate, web thickness, Pont Angle, and Cryogenic Treated Drill Tools that had an impact on the response were determined. It is investigated whether information factors have a main or cooperative effect on normal reactions.