Vertical Milling Machine Research Articles

A FRAME WORK FOR SEAMLESS INTEGRATION OF DESIGN AND MANUFACTURING USING CNC

Machining is an important manufacturing process that is used in a wide range of applications. From aerospace applications to the manufacturing of energy systems we see a major reliance on machining. Nowadays, CNC machining is found in many industries to aid production by manufacturing process. CNC machining is absolutely essential for manufacturing and it is important. Some major benefits of CNC machining is manufacturing are greater efficiency, more accuracy and fabrication. In this project focus on gaining an improved understanding of the mechanics of machining and different factors that contribute to part quality. The aim of this work is to develop a frame work for seamless integration of design and manufacturing using CNC machine. For this process involves some steps. The selection of the component and design a 3D model of the component using CATIA software is presented here. Later generate the tool paths and program (contains G & M codes) using Dell CAM software. A post processor is used to converts the CAM data into specific commands that can be read a machine controller to move the cutting tool along the programmed paths. After the basic selections and decisions the preparation of a program will be done. After the lots of observation will go for fabrication of component using CNC vertical milling machine to achieve a designed shape with smooth finished surface, high accuracy and less machining time which directly increases the productivity.

A FRAME WORK FOR SEAMLESS INTEGRATION OF DESIGN AND MANUFACTURING USING CNC

Machining is an important manufacturing process that is used in a wide range of applications. From aerospace applications to the manufacturing of energy systems we see a major reliance on machining. Nowadays, CNC machining is found in many industries to aid production by manufacturing process. CNC machining is absolutely essential for manufacturing and it is important. Some major benefits of CNC machining is manufacturing are greater efficiency, more accuracy and fabrication. In this project focus on gaining an improved understanding of the mechanics of machining and different factors that contribute to part quality. The aim of this work is to develop a frame work for seamless integration of design and manufacturing using CNC machine. For this process involves some steps. The selection of the component and design a 3D model of the component using CATIA software is presented here. Later generate the tool paths and program (contains G & M codes) using Dell CAM software. A post processor is used to converts the CAM data into specific commands that can be read a machine controller to move the cutting tool along the programmed paths. After the basic selections and decisions the preparation of a program will be done. After the lots of observation will go for fabrication of component using CNC vertical milling machine to achieve a designed shape with smooth finished surface, high accuracy and less machining time which directly increases the productivity.

Study of surface layers of VT41 titanium alloy after mechanical treatment

The work studies residual stresses in the surface layer, roughness of flat surfaces of titanium alloy VT41 sample, obtained by milling with end mills, as well as conditions for relieving these stresses by means of incomplete annealing. The milling was carried out on a universal vertical milling machine, varying the conditions of the machining allowance in one pass and the cutters.

Зміна шорсткості поверхні при нанесенні антифрикційних покриттів

The analysis of literary sources made it possible to state that the surface roughness obtained by the finish anti-friction non-abrasive treatment (FANT) is one of the main quality criteria of the anti-friction coating and largely determines the process of running-in during the initial period of operation. The purpose of the presented research is to establish the main patterns of changes in the roughness of the surface layer treated by FANT. Application of anti-friction coatings was carried out according to the method developed by the authors using the original device on a vertical milling machine. Special disc-shaped samples made of gray cast iron SCH20 were used as the tested samples. L63 brass was used as the material of the anti-friction coating. Among the technological factors that changed with the selected FANT scheme, the following were selected: the pressure force of the anti-friction bar and the number of rubbing passes. The roughness of the surface was estimated by the average arithmetic deviation of the Rа profile. The average value obtained as a result of three measurements was taken as the value of the roughness parameter Rа. The obtained values made it possible to establish the main patterns of changes in the roughness parameter depending on the technological parameters of FANT. It is shown that with an increase in the initial surface roughness parameter Rа, the value of the change in the average arithmetic deviation of the profile Ra also increases. High initial values of the arithmetic average deviation of the Ra profile do not allow obtaining a continuous, and therefore high-quality anti-friction coating of FANT. Obtaining a high-quality anti-friction coating with the selected FANT scheme became possible with the following processing modes: pressing force of the anti-friction bar P = 164.6 N; the number of rubbing cycles is N = 6. The results of the studies performed on the application of FANT anti-friction coatings make it possible to predict and control such an important geometric parameter of the surface layer as roughness, which largely determines the quality of the treated surface.

Influence of cutting parameters on end milling of magnesium alloy AZ31B

Magnesium alloys are having the characteristics like light weight, wear, and corrosion resistance. Mg alloys find usage in a wide range of applications such as engine block of automobile parts, laptop cases, aircraft fuselages and mobile outer cases. However, in dry machining, many challenges restrict its development during fitment. In this research work, conventional vertical milling machine was used to conduct end milling operation on Mg AZ31B alloy with coated carbide insert. End milling operations were performed by varying spindle speed, feed per tooth, and constant cutting depth. The chip morphology and tool chip interface temperature were investigated for various cutting conditions. Also, feed force (Fx), thrust force (Fy) and cutting force (Fz) was analyzed to understand the proper material deformation characteristics.

DVDLWC. SMOOTHING THE WORKING SURFACE DURING RESTORATION OF INTERNAL COMBUSTION ENGINE PARTS

When operating internal combustion engines, there is a problem of restoring cylinder liners. After wear, the cylinder liner is bored to the repair size, using boring and honing machines. Finding new effective processing methods is an urgent task. (Research purpose) The research purpose is smoothing the inner surface of cylinder liners by using a vibration-damping extension cord. (Materials and methods) The article proposes an epoxy-based adhesive composition and metal cables to reduce vibration during processing that ensure the compression state of the entire boring system. A special design of the vibration-damping extension of the boring mandrel have been developed. The article presents its description. A 6P12 vertical milling machine was used for research. Prototypes with an internal diameter of 80 millimeters were manufactured of steel 38 HMUA and steel 20. The Mitutoyo profilometer model SJ-410 was used to measure roughness. The rotation speed was changed from 80 to 500 revolutions per minute. (Results and discussion) The roughness of the surface layer of blanks made of 38HMYuA steel treated with a boring mandrel with a vibration-damping extension is four times higher on average than a traditional boring at all stages of the experiment, the roughness parameter Ra is 0.8. The quality of the surface layer of 20 steel blanks processed with a boring mandrel with a vibration-damping extension is twice as high on average as with a traditional boring at 80-315 rpm, the roughness parameter Ra is 1.6 and four times higher at 315-500 rpm, the roughness parameter Ra is 3.2. (Conclusions) The use of a vibration-damping extension will reduce the cost and complexity of restoring parts of internal combustion engines and remove special boring and internal grinding machines from the technological process.

Examination of microstructure properties of AISI 316L stainless steel fabricated by wire arc additive manufacturing

Wire Arc Additive Manufacturing (WAAM) is a fusion manufacturing or Wire-feed additive manufacturing for creating components by layer-by-layer technique. WAAM has been a viable replacement to traditional machining because of its ecological protection, high deposition rate, minimizes the wastage, and competitive pricing. WAAM technique is used to manufacture multipart designed products.316 L stainless steel plate was fabricated in this investigation using ER 316 L consumable wires and a welding robot system. Current, Voltage, welding speed, gas flow rate, and shielding gas were used as experimental factors. Micro wire cut electric discharge machining was used to remove the base plate and side edges, and the processed plate surface was polished with help of vertical milling machine. To check the microstructure behaviors like Scanning electron microscope, Macro test and Surface roughness test was performed. The process of additive manufacture of 316L stainless steel is found to be practical using this experimental work.

Experimental studies on single point incremental sheet forming of stainless steel 409L alloy

Single Point Incremental Forming (SPIF) is a sheet metal forming process in which a sheet metal blank is plastically deformed through a progressive action of single point tool and more reliable for batch production of complex shape of sheet metals with simple numeric control vertical milling machine. In this study, the formability behaviour of stainless steel 409L on both conventional and incremental forming technique were analysed experimentally. The effect of process parameter of SPIF like tool size, spindle speed, feed rate and vertical step down on the formability of stainless steel 409L was investigated experimentally. The forming limit diagram (FLD) and fracture limit curve (FLC) of SS 409L for both the forming processes were plotted and compared. Formability of SS 409L during SPIF increased comparing with conventional forming technique.

Modelling the effect of slide table mass on machine tool energy consumption: The role of lightweighting

Much of the environmental footprint of a machine tool is due to the energy consumed during its use phase. A promising strategy for reducing this energy consumption is to minimize the mass of components through changes in the design of the machine tool. This paper explores the lightweighting of the machine slides (or tables) to achieve energy savings. An energy model is developed which considers the table and workpiece mass, the cutting force, and the motor that drives the table. A case study is carried out on a three-axis vertical milling machine to explore the energy savings that can be realized via lightweighting a slide table. The model is used to compare the energy consumption of a solid table and a lightweight table. Results show a potential energy savings of up to 38% in terms of the energy required to move the table. The model is verified using experimental data already found in the literature. It was observed that the model has a lower prediction capability when the table speed and power demand are very low but as the speed and power increase the prediction capability increases significantly.

Development of a Cost Model for Vertical Milling Machines to Assess Impact of Lightweighting

Lightweighting is a design strategy to reduce energy consumption through the reduction of mass of a product. Lightweighting can be applied to machine tools to reduce the amount of energy consumed during the use phase. Thus, the energy cost of machine operation will be reduced. One might also hypothesize that since a lighter-weight machine tool requires less material to build, the cost to produce such a machine will be less. However, it may also be the case that lightweighting a machine tool increases its complexity, which will likely drive up the cost to manufacture the machine. To explore the cost drivers associated with building a machine tool, data on the features associated with a wide variety of vertical milling machine tools are collected. Then, empirical cost models are fit to this data. The results from the cost models show that the machine tool mass is a significant cost driver; other key drivers are the number of axes and spindle power. The models are used to predict the cost benefits of lightweighting in terms of mass, which are compared to potential increased manufacturing costs associated with complexities introduced due to lightweighting.

Multi-Response Optimization of process Parameter in Vertical Milling Machine of EN 31 Using Taguchi Method

The purpose of this experimental research is to compare the effectiveness of using Taguchi approaches for multi-response optimization of process parameters in Vertical Milling Machine of EN 31 Material intending to minimize surface roughness and tool wear rate while maximizing material removal rate to improve the productivity of the process with coated carbide insert. Taguchi L9 and Annova have been applied for experimental design and analysis. This experiment shows that feed and depth of cut are factors that are important for tool wear, Depth of cut is a notable factor for Material Removal Rate and feed is the most notable factor for surface roughness. Spindle speed has little effect on tool wear rate, surface roughness, and material removal rate. Mathematical models for three response parameters i.e. tool wear rate, surface roughness, and material removal rate were obtained by regression analysis

Experimental investigation on magnetorheological finishing process parameters

Magneto-rheological polishing (MRP) fluid was developed by MR fluid using a magnetic field, non-magnetic abrasives such as SiC and Al2O3, and carrier medium like oil. A magnetic polishing tool was developed using a super-strong permanent neodymium magnet (Nd2Fe14B) with 0.5-tesla magnetic intensity. This polishing tool was assembled to the vertical milling machine for the finishing workpieces. In the present research, magnetic materials (steel material) and non-ferromagnetic (copper) content were finishing using a developed MRP setup for experimental investigation. This research also investigated the parametric dependencies of different abrasives on the magneto-rheological finishing process. It determined the effect of magnetic particle concentration and abrasives on the surface roughness of ferromagnetic (stainless steel) and non-ferromagnetic material (copper). The final surface roughness value has reached 30 nm from its initial surface roughness of 800 nm for non-ferromagnetic (copper). For the magnetic material (stainless steel), the value is 50 nm from 1300 nm.

Evaluation of shear force and fractography of friction stir spot welded joints of AA 6082-T6 alloy

This experimental work investigates the tensile behavior of friction stir spot welded joints from 3 mm thick aluminum alloy AA6082-T6 sheets. Taguchi L9 Orthogonal array was used for process parameters - Tool rotational speed (TRS), Dwell time (DT) and Shoulder diameter (SD) with consideration of three levels. Friction Stir Spot Welding (FSSW) was performed on vertical milling machine. Tensile shear test was conducted on Universal testing machine (UTM) to find out the tensile shear failure load (TSFL). The optimal combinations of parameters were at tool rotational speed of 2,000 rpm, dwell time of 15 seconds and tool shoulder diameter of 16 mm. Tool rotational speed had a substantial effect on tensile shear strength of FSSW joint. Scanning Electron Microscopy (SEM) tests revealed that the changes in microstructure in different zones of FSSW joint were observed. Tensile shear specimen was analyzed using SEM to observe the behavior of fracture surfaces. Significant ductility in the fracture surface was an evident in the fractography. In this article, attention is focused on the influence of joining parameters on the mechanical behavior of the friction stir spot weld under the tensile shear load condition. Keywords: Fractography; friction stir spot welding (FSSW); heat affected zone (HAZ); scanning electron microscopy (SEM); thermo-mechanically affected zone (TMAZ).

Cyber Physical Systems implementation to develop a Smart Manufacturing

This paper aims to show how the Cyber Physical Systems (CPS) are able to transform the actual manufacturing process. For that purpose, a case of study has been developed as an example of how to implement a CPS in a machine tool, specifically a 5-axis vertical milling machine of the Haas brand. This CPS transforms the acquisition of real-time data into worthy information for the industry. CPS implementation consists of 5 levels, which are explained and exemplified in this study. As a result of the implementation, it is shown a real-time indicator which takes part of our research. Our study concludes that CPS implementation enhance and speed up the decision-making of the companies.

Internet of Things Based Cutting Tool Status Monitoring in a Computer Numerical Control Milling Machine

The Internet of Things (IoT) in the manufacturing industry shares machine data in real time. The majority of industrial data can be gathered and processed from machines and other remote IoT devices in a production system through data streaming. As sensors become smaller and more affordable, the Internet of things will attract more attention. It is possible to employ a wide range of sensors for monitoring, and with efficient open-source software, the status of the operation can be evaluated effectively. Our work aims at providing instructions for sending data (cutting tool status time) from Particle Photon devices connected to CNC milling machines to open-source software called ThingSpeak. This task is accomplished by integrating the Particle Photon device with the infrared sensor to the CNC milling machine. Three axis CNC vertical milling machine is used to manufacture the sample component. The status of the cutting tool, in this case the cutting time for each machining feature is monitored. Using infrared technology, the sensor detects whether the cutting tool is present. Particle photons measure machining time and communicate it to ThingSpeak. The ThingSpeak library will interpret the cloud information and displays it. With ThingSpeak software, we define the fields for various cutting tools and track every tool in real time. The time recorded using ThingSpeak software is found to be near to the time, which is monitored manually by the user. A major step in computer assisted process planning in manufacturing is monitoring the machining time for each cutting tool and it is successfully implemented in this research work.

Fabrication of Aluminium Metal Matrix Composite by Friction Stir Processing

Friction Stir Processing (FSP) is a new approach for successful fabrication of Aluminium Metal Matrix Composites (AMCs) with required properties of Nitinol (NiTi) Shape Memory Alloys (SMA). This reinforcement agent is used for heightening the mechanical properties of aluminium alloy with Shape Memory Effect but such fabrication was not possible without defects such as critical intermetallic formation between reinforced particles and matrix. So we present a creative strategy to fabricate Al7075-T6/NiTi composites by FSP. It has been found that the groove filling method results in a more homogenous distribution compared to the multi-holes filling method. In this innovative strategy, we are going to use the groove filling method with a new FSP tool design for the linear distribution of reinforcement particles in grooves. This FSP tool will be used with the help of a Vertical Milling Machine.

Wear Behavior of Ceramic-Metal Composites as Tool Material for FSW of Copper

Friction stir welding (FSW) is employed primarily for metals characterized by poor weldability at fusion welding: aluminium, magnesium, titanium and copper alloys as well as stainless steels. The focus of the study was on the feasibility of application of WC-based hardmetal 85WC-Co and TiC-based cermet 80TiC-NiMo as potential tool materials for FSW of copper. The single-pass welding trials of Cu sheets were performed using a vertical milling machine. For better understanding of interactions between the tool and workpiece at welding temperature EDS line scans across the interfaces tool-workpiece after welding as well as after diffusion tests were performed. It was concluded that both tested ceramic-metal composites did not failure during multiple plunges and during the total transverse welding distance of 10 m. Also, significant tool wear was not observed after such a welding distance. The possibility of producing visually defect-free welds using tools from WC- and TiC- based ceramic-metal composites was proved and also mutual diffusion of elements across the interface tool-workpiece was discussed.

Acceleration-Dependent Analysis of Vertical Ball Screw Feed System without Counterweight

The distinguishing feature of a vertical ball screw feed system without counterweight is that the spindle system weight directly acts on the kinematic joints. Research into the dynamic characteristics under acceleration and deceleration is an important step in improving the structural performance of vertical milling machines. The magnitude and direction of the inertial force change significantly when the spindle system accelerates and decelerates. Therefore, the kinematic joint contact stiffness changes under the action of the inertial force and the spindle system weight. Thus, the system transmission stiffness also varies and affects the dynamics. In this study, a variable-coefficient lumped parameter dynamic model that considers the changes in the spindle system weight and the magnitude and direction of the inertial force is established for a ball screw feed system without counterweight. In addition, a calculation method for the system stiffness is provided. Experiments on a vertical ball screw feed system under acceleration and deceleration with different accelerations are also performed to verify the proposed dynamic model. Finally, the influence of the spindle system position, the rated dynamic load of the screw-nut joint, and the screw tension force on the natural frequency of the vertical ball screw feed system under acceleration and deceleration are studied. The results show that the vertical ball screw feed system has obviously different variable dynamics under acceleration and deceleration. The influence of the rated dynamic load and the spindle system position on the natural frequency under acceleration and deceleration is much greater than that of the screw tension force.

Effect of Surface Finishing on Microstructure and Corrosion Behavior of Friction Stir Welded Joints For Dissimilar Aluminum Alloys (AA2024-T3 with AA6061-T6)

The aim of this work is to study the possibility of joining two plates from aluminum alloys, AA2024-T3 with AA6061-T6, using friction stir welding (FSW) technique. In this study, the plates were prepared by cutting with dimensions (100 x 50 x 5) mm by CNC milling machine with cutting speed of 1200 rpm and variable feeding speed of (25, 30, 35 & 40 mm/min). The FSW was operated by a vertical milling machine at a rotary speed of 930 rpm and linear welding speed of 30 mm/min to obtain welding joints of dissimilar plates. Microstructure, surface roughness and micro-hardness were examined. Corrosion test was also carried out by electrochemical methods for all specimens in 3.5wt % NaCl solution, and the corrosion rate was calculated by Tafel extrapolation method. The obtained results demonstrated that the feeding speed has a significant effect in decreasing the corrosion rate comparing with the base metal due to the plastic deformation that occurs at high feed speed. The decrease in surface roughness provided more connected between the two contact surfaces that contributed in the refinement of the microstructure. The sample welded at feed speed 40 mm/min offered the optimum results.

The vibration analysis of the CNC vertical milling machine spindle system considering nonlinear and nonsmooth bearing restoring force

The performance improvement of the computer numerically controlled (CNC) vertical milling machine is constrained by limited understanding of the dynamic behaviors of the spindle system. In order to study the dynamic characteristics of the CNC vertical milling machine spindle system under unbalanced force, the lumped mass method is applied to propose a novel dynamic model. In this comprehensive model, Hertz contact, radial clearance and time-varying stiffness of rolling bearings are considered. According to the contact behaviors of rolling bearings supporting the spindle, restoring force is a nonsmooth and nonlinear function of displacements and bearing radial clearance. Then, governing differential equations of the eighteen-degree-of-freedom system are derived using the Lagrange equation. In addition, the effectiveness of this dynamic model is verified by experiments. The influences of spindle speed and the bearing parameters on the vibration behaviors and stability of the spindle are analyzed by amplitude-frequency curve, bifurcation diagram, time domain waveform, spectrum diagram, trajectory and Poincaré. Moreover, we discussed how the dynamics of the spindle are affected by the eccentricity of the belt pulley, the extended length of the milling tool, and the position of the intermediate bearing set. The research results can benefit the structural design of the spindle, optimize the bearings selection, as well as improve the machining accuracy.