... Abstract This paper presents novel adaptive spindle speed control strategies to minimize machining vibrations. Machining processes suffer from forced and chatter vibrations that deteriorate surface finish, reduce tool life and can damage the machine components. Model-based process planning...

... and efficacy in manufacturing simulations. digital twin design finite element analysis manufacturing end mills stress and strain machining Proceedings of the ASME 2024 19th International Manufacturing Science and Engineering Conference MSEC2024 June 17-21, 2024, Knoxville, Tennessee MSEC2024...

... by detailed contour machining. To demonstrate this concept, a custom-built 3-axis machine with separate heads for printing and machining was developed. This study alters the parameters of nozzle diameter (0.4 and 0.8 mm) and the printing speed (3600 and 9000 mm/min) to print two generic parts with drastically...

... a central challenge. This problem is particularly acute since material flow near free surfaces and interfaces is paramount for understanding the mechanics of several deformation processing configurations, such as machining and forming. Two common DIC implementations exist, and they exploit either local...

... Abstract Titanium (Ti) alloys are classified as difficult-to-machine materials due to low thermal conductivity, low modulus, and high chemical reactivity. In this paper, a Ti-6Al-4V alloy bar in a solution treated and aged (STA) microstructure is turned using uncoated carbide, two commercial...

... digital process twins (DPTs). The SC Scrap cost utility of the DPT approach is demonstrated for the case of finish SR Scrap rate machining of aerospace components made from gamma titanium Tooling per part aluminide alloy TiAl). This particular component has been TC plagued with persistent quality defects...

... Abstract When chatter vibrations occur during cutting, a characteristic pattern called chatter mark appears on the machined surface. In our previous studies, it was estimated that this chatter mark is formed by the tool (or workpiece) vibration in the normal direction with respect...

... Abstract The deformation conditions in machining of metals and alloys offer a unique route for materials processing with remarkable advantages over conventional deformation processes. The intense shear strain and high strain-rates in machining can be applied to form chips with controlled...

... speed of 50 m/min. The microstructures of the machined chips indicate that dry machining had the highest percentage of b-phase indicating higher phase transformation owing to higher tool temperature. The b-phase was found to be the least in MQL machining chips, which is very similar...

... that capture the deformation physics while being computationally feasible. Moreover, even conventional standard FEA codes can be leveraged for modeling and simulation in more effective ways. In this work, we present three challenging scenarios for modeling, namely large strain extrusion machining (LSEM...

... Abstract The effects of surface structure on mechanical performance for open-cell aluminum foam specimens was investigated in the present study. A surface gradient for pore structure and diameter was introduced into open cell aluminum foams by machining-based processing. The structure changes...

... mechanisms (termed the electroplastic effect ). It is envisioned that this approach, currently applied to bulk/sheet deformation, could also be used to reduce the flow stress in the deformation zone of the machining shear plane. The objective of this work is to study and model the effect of electric current...

... Bio-ceramics have been widely employed in dental restorations, repairing bones, and joint replacements etc. due to their high compressive strength, superior wear resistance, and natural aesthetical appearance. Abrasive machining processes such as grinding have been used to obtain a smooth...

... The atomization–based cutting fluid (ACF) spray system has recently been proposed as a cooling and lubrication solution for machining hard to machine materials (e.g. titanium alloys). On the tool rake face, the ACF spray system forms a thin film from cutting fluid that penetrates into the tool...

... of carbide tools when machining Ti-6Al-4V. To capture the tool substrate response, controlled milling experiments are conducted at suitable corner points of the feed-speed design space for constant stock material removal volumes. For each case, the tool material volumes worn away, as well...

... STEP-NC is a new data format for manufacturing control. One of its applications is to enable integrated on machine measurement of machining processes using vision systems and other sensors. In this paper we describe the manufacturing process and manufacturing resource models in STEP-NC that can...

... 19 09 2011 The objective of this paper is to qualitatively assess the inadequacies of the current manner of tool wear quantification and consequently to suggest/develop a more comprehensive approach to machining tool wear characterization. Traditional parameters used for tool wear...

... 19 09 2011 A mechanistic model for cutting force in ultrasonic-vibration-assisted grinding (UVAG) (also called rotary ultrasonic machining) of brittle materials is proposed for the first time. Fundamental assumptions include: (1) brittle fracture is the dominant mechanism of material...

... 22 04 2011 Tool abrasion and material adhesion lead to tool flank wear and flank build-up respectively in machining magnesium alloys, which adversely affect surface integrity due to higher cutting forces and temperatures. In this paper, a novel on-line optical tool monitoring system...

... 22 09 2010 Machining wear models are useful for the prediction of tool life and the estimation of machining productivity. Existing wear models relate the cutting parameters of feed, speed, and depth of cut to tool wear. The tool wear is often reported as changes in flank width...