• Title/Summary/Keyword: Tool rotation speed

Search Result 122, Processing Time 0.025 seconds

Calculating the Feedrate of 5-Axis NC Machining Data for the Constant Cutting Speed at a CL-point (공구 끝의 일정한 절삭속도를 위한 5축 NC 가공 데이터의 이송속도 산출)

  • 이철수;이제필
    • Korean Journal of Computational Design and Engineering
    • /
    • v.6 no.2
    • /
    • pp.69-77
    • /
    • 2001
  • This paper describes a method of calculating the feedrate for the constant cutting speed at a CL-point in 5-axis machining. Unlike 3-axis machining, 5-axis machining has the flexibility of the tool motions due to two rotation axes. But the feedrate at joint space differs from the feedrate at a tool tip(the CL-point) of the 3D Euclidean space for the tool motions. The proposed algorithm adjusts the feedrate based on 5-axis NC data, the kinematics of a machine, and the tool length. The following calculations is processed for each NC block to generate the new feedrate; 1) calculating the moving distance at the CL-point, 2) calculating the moving time by the given feedrate, 3) calculating the feedrate of each axis, 4) getting the new feedrate. The proposed algorithm was applied to a 5-axis machine which had a tilting spindle and a rotary table. Totally, the result of the algorithm reduced the machining time and smoothed the cutting-load by the constant cutting speed at the CL-point.

  • PDF

Characteristics of Dissimilar Materials Al alloy(A6005)-Mg alloy(AZ61) Under Friction Stir Welding for Railway Vehicle (철도차량 적용을 위한 Al alloy(A6005)-Mg alloy(AZ61) 이종소재 마찰교반용접 특성 연구)

  • Lee, Woo-Geun;Kim, Jung-Seok;Sun, Seung-Ju;Lim, Jae-Yong
    • Journal of the Korea Academia-Industrial cooperation Society
    • /
    • v.17 no.8
    • /
    • pp.706-713
    • /
    • 2016
  • In this study, the welding characteristics of friction stir welding were investigated in accordance with the tool plunge position and cooling to the base materials for the joining of dissimilar materials (A6005-AZ61). Other different welding conditions, such as the tool rotation speed and welding speed, were fixed to 500rpm-30mm/min, respectively, and welding was then carried out by placing the Mg alloy (AZ61) on the advancing side and Al alloy(A6005) on the retreating side. Welding was conducted under six different conditions. To investigate the welding characteristic, tensile test and microstructure observations using an optical microscope were carried out. As the tensile test result, the maximum strength appeared under the condition in which the tool is moved 1 mm to the Mg alloy direction and cooling to the base materials. Under the same welding conditions, the strength with cooling was approximately two times higher than that without cooling. The tool was located in each direction of 1.7 mm from the weld line. Therefore, in the excessive off-set of tool position, the welding integrity was in an extremely poor condition due to the lack of stirring. This study was confirmed by the A6005-AZ61 dissimilar friction stir welding the welding speed and the tool rotation speed. In addition, the temperature control and tool plunge position are important welding parameters.

Fabrication of Micro Tool Electrode for Machining Micro Structures using Wire Electrical Discharge Grinding(WEDG) (WEDG 방법을 이용한 마이크로 구조물 가공용 미세공구 제작)

  • Park Sung-Jun;Ahn Hyun-Min;Lee Kyo-Seung
    • Transactions of the Korean Society of Machine Tool Engineers
    • /
    • v.14 no.5
    • /
    • pp.13-20
    • /
    • 2005
  • Micro EDM process is generally used for machining microholes, cavities, and three dimensional shapes. For machining micro structures, first of all, micro tool electrode is indispensable and WEDG system is proposed for tool fabrication method. When using WEDG, its machining characteristics are highly affected by many EDM parameters such as applied voltage, current, rotation speed, capacitance, and pulse duration. Therefore, the design of experiment is introduced to fully understand the effect of the EDM parameters on machining tool electrode. And an attempt has been made to develop the mathematical model for predicting the size of the tool electrode by calculating spark distance. The suggested model was verified with experiment and predicted working gap distance is in good accord with the measured value.

A Study on the Influence of Nonlinearity Coefficients in Air-Bearing Spindle Parametric Vibration

  • Chernopyatov, Y.A.;Lee, C.M.;Chung, W.J.;Dolotov, K.S.
    • International Journal of Precision Engineering and Manufacturing
    • /
    • v.6 no.1
    • /
    • pp.51-58
    • /
    • 2005
  • The development of the high-efficiency machine-tools equipment and new cutting tool materials with high hardness, heat- and wear-resistance has opened the way to application of high-speed cutting process. The basic argument of using of high-speed cutting processes is the reduction of time and the respective increase of machining productivity. In this sense, the spindle units may be regarded as one of the most important units, directly affecting many parameters of high-speed machining efficiency. One of the possible types of spindle units for high-speed cutting is the air-bearing type. In this paper, we propose the mathematical model of the dynamic behavior of the air-bearing spindle. To provide the high-level of speed capacity and spindle rotation accuracy we need the adequate model of "spindle-bearings" system. This model should consider characteristics of the interactions between system components and environment. To find the working characteristics of spindle unit we should derive the equations of spindle axis movement under the affecting factors, and solve these equations together with equations which describe the behavior of lubricant layer in bearing (bearing stiffness equations). In this paper, the three influence coefficients are introduced, which describe the center of spindle mass displacement, angle of shaft rotation around the axes under the unit force application and that under the unit torque application. These coefficients are operated in the system of differential equations, which describes the spindle axis spatial movement. This system is solved by Runge-Kutta method. Obtained trajectories and amplitude-frequency characteristics were then compared to experimental ones. The analysis shows good agreement between theoretical and experimental results, which confirms that the proposed model of air-bearing spindle is correctis correct

Effect of Welding Condition and Tool Shape on Defect Formation of Extruded AA6005 with Non-uniform Thickness using Load-Controlled Friction Stir Welding Technique (두께 불균일 AA6005 압출재의 하중제어 마찰교반접합에서 접합 조건과 툴 형상이 결함발생에 미치는 영향)

  • Yoon, Tae-Jin;Kang, Myung-Chang;Jung, Byong-Ho;Kang, Chung-Yun
    • Journal of the Korean Society of Manufacturing Process Engineers
    • /
    • v.12 no.6
    • /
    • pp.45-51
    • /
    • 2013
  • Friction stir welding using aluminum alloys has been widely applied for transportation vehicles because of the light specific weight, which can be used to obtain sound joint and high mechanical properties. This study shows the effects of rotation speed, welding speed, welding load, and tool shape on defect formation with extruded AA6005, which is used for railway vehicle structures of non-uniform thickness welded by friction stir welding using load control systems. Optical microscopy observations and liquid penetrant testing of each FSW joint were carried out in order to observe defect formation. Two kinds of defects, that of probe wear and that of lack of penetration in the bottom of the welded zone, were observed. In the case of using a taper shaped tool, the defect free zone is very narrow, within 100 kgf; however, in case of using a cylindrical shape tool, the defect free zone is wider.

A Study on the Manufacturing Characteristics for Micro Spherical Lens Mold of Soft Materials (연질재료의 마이크로 구형렌즈금형 가공특성에 관한 연구)

  • 홍성민;이동주;제태진;최두선;이응숙
    • Proceedings of the Korean Society of Precision Engineering Conference
    • /
    • 2004.10a
    • /
    • pp.1466-1469
    • /
    • 2004
  • Micro spherical lens mold processing method based on mechanical one completes a spherical shape by setting a diamond tool of hundreds $\mu$m radius on spins with high speed and then using Z-axis vertical feeding motion like the fabrication of micro drilling. In this method, we can see unprocessed parts shaped like cylinder and cone and check increasing chatter marks and burrs by setting errors of the central axis of rotation on the edge of the tool. That is why this method doesn't suit for the optical lens mold. In this paper presents unprocessed parts are disappeared and chatter marks and burrs are decreased from centre of the lens after using Run-out measuring and setting system on run-out occurred from setting tool. Also the fabrication characteristics of 6:4 Brass, A1601, PMMA are compared and analyzed, establishing the optimum machining condition on each material.

  • PDF

Study on the Manufacture of Resin Concrete of Machine Tool Bed with High Damping Capacity (고감쇠 레진 큰크리트 공작기계 베드 제작에 관한 연구)

  • 서정도;방경근;이대길;김태형;박보선
    • Proceedings of the Korean Society of Precision Engineering Conference
    • /
    • 1997.10a
    • /
    • pp.429-433
    • /
    • 1997
  • High-speed and high-precision are trendy at present in the development of machine tools which are required for various fields of industry such as semiconductor, automobde, mold fabricat~on and so on. High damping capacity of the structure is an iniportant factor to ohtain precise products without vibration during manufacturing caused by rapid trarisportatm and rotation of spindle unit Resin concrete have high potential for machine tool bed due to its good damping characteristics. In this study, the statlc and dynamic characteristics of the machine tool bed were analysed. Also, the hybrid machine tool bed, made of steel base and polyester resin concrete material, was manufactured and its good dynamic characteristics were proved experimentally.

  • PDF

Optimization of Cutting Force for End Milling with the Direction of Cutter Rotation (엔드밀가공에서 커터회전방향에 따른 절삭력의 최적화)

  • Choi, Man Sung
    • Journal of the Semiconductor & Display Technology
    • /
    • v.16 no.2
    • /
    • pp.79-84
    • /
    • 2017
  • This paper outlines the Taguchi optimization methodology, which is applied to optimize cutting parameters in end milling when machining STS304 with TiAlN coated SKH59 tool under up and down end milling conditions. The end milling parameters evaluated are depth of cut, spindle speed and feed rate. An orthogonal array, signal-to-noise (S/N) ratio and analysis of variance (ANOVA) are employed to analyze the effect of these end milling parameters. The Taguchi design is an efficient and effective experimental method in which a response variable can be optimized, given various control and noise factors, using fewer resources than a factorial design. An orthogonal array of $L_9(33)$ was used. The most important input parameter for cutting force, however, is the feed rate, and depending on the cutter rotation direction. Finally, confirmation tests verified that the Taguchi design was successful in optimizing end milling parameters for cutting force.

  • PDF

Effect of Circumferential Tool Path Control on Friction Stir Spot Welding of Al/Fe Dissimilar Metal Joint (툴 경로제어를 이용한 Al/Fe 이종금속 마찰교반점용접 공정특성 평가)

  • Yoon, Jin Young;Kim, Cheolhee;Rhee, Sehun
    • Journal of Welding and Joining
    • /
    • v.34 no.3
    • /
    • pp.6-11
    • /
    • 2016
  • Joining Al/Fe dissimilar metals is becoming a subject of special interest in the assembly of automotive parts as a trade-off between the weight lightening and the cost reduction. Although various studies have been introduced to join Al alloy with the steel sheet by fusion welding, weak joint strength and galvanic corrosion still remained as problems to be solved. As a solid state welding, friction stir welding has been preferred to fusion welding processes in the dissimilar metal joints. This study investigated friction stir spot welding (FSSW) of Al alloy to the thin steel sheet with a thickness of 0.65 mm. The conventional FSSW is a stationary spot welding process but new approach adopted an additional circumferential movement in company with high speed tool rotation. A full factorial experimental design was implemented, and the main and interaction effects of parameters were analysed on the failure load in the tensile shear test. The direction and radius of rotation were statistically significant parameters and these two parameters affected the joint width and the shape of the hook.

The Effect of Welding Condition on Tensile Properties of Friction Stir Welds of KS5J32 Al Alloy (KS5J32 Al합금 마찰교반접합부의 인장성질에 미치는 접합조건의 영향)

  • Yoon, Tae-Jin;Kim, Sang-Ju;Kim, Nam-Kyu;Song, Sang-Woo;Kang, Chung-Yun
    • Journal of Welding and Joining
    • /
    • v.29 no.5
    • /
    • pp.82-89
    • /
    • 2011
  • The effect of welding condition on tensile properties of KS5J32 Al Alloy was investigated under various welding conditions. The 1.6 mm thick KS5J32 alloy sheets were joined by friction stir welding (FSW) technique with butt joint. The tool rotation speeds were 1000, 1250 and 1500 rpm, and the welding speeds were varied within the range from 100 to 600 mm/min. Voids mainly occurred at the advancing side of the tool probe, when the tool rotation speed was low, due to insufficient materials flow. When the weld pitch exceeded 0.4 mm/rev, voids were observed under all welding conditions and the area of voids increased with increasing weld pitch. For void-free specimens, fracture always occurred at base materials. However voids affected the location of fractures, base metal or welded zone, when the voids existed within the welds.