• Title/Summary/Keyword: High speed end milling

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HIGH-SPEED MILLING FOR DIE AND MOLD MAKING

  • Na, T.kagawa
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2000.06a
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    • pp.51-60
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    • 2000
  • High-speed milling machine is being sold mainly in the market of die and mold industries, because it reduces machining time greatly as proportion to the spindle speed of machine tool. From the experimental milling tests, it has been cleared that the ball end mill is quite suitable for high speed milling and also tool wear reduces in higher speed milling condition. And a new milling concept with ultra high speed over 100, 000 rpm is proposed for solving the various problems such as NC cutter path generation and NC feed conformity etc.

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Simulation of surface profile using accelerometer in high speed end milling (고속 엔드밀 가공시 가속도계를 이용한 표면형상 시뮬레이션)

  • 이기용
    • Proceedings of the Korean Society of Machine Tool Engineers Conference
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    • 2000.04a
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    • pp.321-325
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    • 2000
  • To obtain precise surface and high productivity, high speed end milling has been studied recently. Though high speed end milling is explicitly effective for precision surface generation geometrically, tool deflection, chatter vibration and frequency characteristics of end milling system deteriorate the theoretical surface. In this study, simulation algorithm and programming method are suggested to simulate machined surface using acceleration signal in high speed end milling. This simulation is conducted by considering vibrational effect of spindle system which was not considered by other researchers. Between simulated results and experiment results, good agreements were obtained.

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Simulation of Machined Surface Considering Acceleration Signal in High Speed End Milling (고속 엔드밀 가공시 가속도 신호를 고려한 가공표면의 시뮬레이션)

  • Lee, Gi-Yong;Gang, Myeong-Chang;Lee, Deuk-U;Kim, Jeong-Seok
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.25 no.2
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    • pp.228-234
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    • 2001
  • To obtain precise machined surface and high productivity in machining, high speed end milling has beed studied recently. Though high speed end milling is explicitly effective for precision surface generation geometrically, tool deflection, chatter vibration and frequency characteristics of end milling system deteriorate the theoretical surface. In this study, simulation algorithm and programming method are suggested to simulate machined surface using acceleration signal in high speed end milling. This simulation is conducted by considering vibrational effect of spindle system which was not considered by other investigators. Good agreements were obtained between simulated results and experimental results.

Application of Statistical Analysis for Working Factors Effect of High Speed End-Milling for STD61 (열간금형용강의 고속 엔드밀 가공인자의 영향에 대한 통계적 분석의 적용)

  • Bae, Hyo-Jun;Lee, Sang-Jae;Woo, Kyu-Sung;Park, Heung-Sik
    • Proceedings of the KSME Conference
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    • 2004.04a
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    • pp.1148-1153
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    • 2004
  • Recently the high speed end-milling processing is demanded the high-precise technique with good surface rougj1ness and rapid time in aircraft, automobile part and molding industry. The working factors of high speed end-milling has an effect on surface roughness of cutting surface. Therefore this study was carried out to analyze the working factors to get the optimum surface roughness by design of experiment. From this study, surface roughness have an much effect according to priority on Spindle speed, feed rale, hardness and axial depth of cut By design of experiment, it is effectively represented shape characteristics of surface roughness in high speed end-milling And determination($R^2$) coefficient of regression equation had a satisfactory reliability of 89.7% and regression equation of surface roughness is made by regression analysis.

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Analysis of Working Factors for Improvement of Surface Roughness on High Speed End-Milling (엔드밀 고속 가공시 표면정도 향상을 위한 가공인자의 영향 분석)

  • 배효준;박흥식
    • Journal of the Korean Society for Precision Engineering
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    • v.21 no.6
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    • pp.52-59
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    • 2004
  • Recently the high speed end-milling processing is demanded the high-precise technique with good surface roughness and rapid time in aircraft, automobile part and molding industry. The working factors of high speed end-milling has an effect on surface roughness of cutting surface. Therefore this study was carried out to analyze the working factors to get the optimum surface roughness by design of experiment. From this study, surface roughness have an much effect according to priority on distance of cut, feed rate, revolution of spindle and depth of cut. By design of experiment, it is effectively represented shape characteristics of surface roughness in high speed end-milling. And determination($R^2$) coefficient of regression equation had a satisfactory reliability of 76.3% and regression equation of surface roughness is made by regression analysis.

Optimization cutting speed in high speed ball end milling (고속 볼 엔드밀 가공에서 절삭속도 최적화)

  • 김경균;강명창;정융호;이득우;김정석
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2001.04a
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    • pp.895-898
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    • 2001
  • This paper presents an optimization cutting speed(OCS) program developed to improve the machining precision and tool life in high speed machining using ball end milling. This program optimized the cutting speed that is changing at any time in free surface machining of an automobile part like a connecting load die. The technique of optimization cutting speed makes the CAD/CAM-generated NC code go through a reverse post process, conducts cutting simulation, and obtain the effective tool diameter of the ball end milling. Then it changes the spindle revolution to within the range of critical cutting speed fit for the material of the workpieces depending upon the effective tool diameter. In this study, the machining precision and tool life were compared for the two connecting load dies processed using the general cutting method and the proposed optimization cutting speed technique, respectively.

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Topography Analysis in High Speed Working by Flat Endmill (엔드밀에 의한 고속가공시 표면형상 해석)

  • Bae, H.J.;Lee, S.J.;Seo, Y.B.;Park, H.S.
    • Journal of the Korean Society of Manufacturing Process Engineers
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    • v.1 no.1
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    • pp.79-88
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    • 2002
  • High speed machining system have been used in industrial because it is effective to a material manufacturing with various shape. Recently the end-milling processing is needed the high-precise technique with good surface roughness and rapid time in aircraft, automobile part and molding industry. Therefore this study proposed to decide best manufacturing cutting condition for surface roughness and rapid manufacturing tune by using computer Image processing system and 3D modelling. Until the 16,000 rpm, the surface roughness is decreased rapidly, but it is not over that. The 22,000 rpm is the spindle speed with the optimum surface in the high speed end-milling. In the case of the feed rate with 2,000 mm/mm and 8,000 mm/mm, the surface roughness is better than 4,000 mm/min and 6,000 mm/min. By using the 3D modelling, it is effectively represented shape characteristics of working surface m high speed end-milling.

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A Characteristic of High Speed Ball End Milling Machining using The Air-Spindle (공기 정압 스핀들을 이용한 고속 볼엔드밀링 가공특성 평가)

  • 이종렬;안선일;안지훈;이득우
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • 2000.05a
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    • pp.922-925
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    • 2000
  • Generally, the machining accuracy in ball end milling directly depends on the rotational accuracy affected by the spindle speeds. The effects of spindle speeds for rotational accuracy in the high speed regions are more dominant than those in the low speed regions. This paper will investigate effects that the Increased speed affects on the rotational error according to the increase of a rotational speed and machining characteristics of the high speed ball-end milling in various rotational speeds and on various materials by using the high speed air-bearing spindle.

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Selection of Machining Inclination Angle of Tool Considering Tool Wear in High Speed Ball End Milling (고속 볼앤드밀링에서 공구마모를 고려한 공구의 가공경사각 선정)

  • Ko, Tae-Jo;Jung, Hoon;Kim, Hee-Sool
    • Journal of the Korean Society for Precision Engineering
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    • v.15 no.9
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    • pp.135-144
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    • 1998
  • High speed machining is a key issue in die and mold manufacturing recently. Even though this technology has great potential of high productivity. tool wear accelerated by high cutting speed to the hardened materials is other barrier. In this research, we attempted to reduce tool wear by considering tool inclination angle between tool and workpiece. The boundary lines describing machined sculptured surfaces were represented by both of cutting envelop condition and the geometric relationship of successive tool paths. Chip cross section, and cutting length could be obtained from the calculated cutting edge and the rotational engagement angle. From the simulation results, machining inclination angle of tool of $15^\circ$ was good enough from the point of tool wear and cutting force, and this value was verified through the cutting experiment of high speed ball end milling.

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Prediction of Surface Topography by Dynamic Model in High Speed End Milling (고속 엔드밀 가공시 동적 모델에 의한 표면형상 예측)

  • Lee, Gi-Yong;Ha, Geon-Ho;Gang, Myeong-Chang;Lee, Deuk-U;Kim, Jeong-Seok
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.24 no.7 s.178
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    • pp.1681-1688
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    • 2000
  • A dynamic model for the prediction of surface topography in high speed end milling process is developed. In this model the effect of tool runout, tool deflection and spindle vibration were taken in to account. An equivalent diameter of end mill is obtained by finite element method and tool deflection experiment. A modal parameter of machine tool is extracted by using frequency response function. The tool deflection, spindle vibration chip thickness and cutting force were calculated in dynamic cutting condition. The tooth pass is calculated at the current angular position for each point of contact between the tool and the workpiece. The new dynamic model for surface predition are compared with several investigated model. It is shown that new dynamic model is more effective to predict surface topography than other suggested models. In high speed end milling, the tool vibration has more effect on surface topography than the tool deflection.