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Hybrid machining: abrasive waterjet technologies used in combination with conventional metal cutting

Wanner B., Archenti A., Nicolescu C. M.

Journal of Machine Engineering

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2017

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Vol. 17, No. 3

85--96

EN

Abrasive Waterjet technology is one of the fastest growing metal cutting technologies. Even so, very little published material is available on hybrid processing where abrasive waterjet cutting is one of two or more metal cutting methods. There is also limited published material on thin-walled components cut with abrasive waterjet technology. This paper makes a comparison of conventional metal cutting methods to the more unconventional abrasive waterjet technique. It will serve as a stepping stone in building knowledge aiding in hybrid machining development. It will show the possibilities and limitations during milling of thin-walled Aluminum components and then compare this to the capabilities of abrasive waterjet cutting the same components. Differences in material removal and revert control as well as in vibrations and force requirements will be reviewed. In addition, the environmental issues will be discussed and it will be determined which of the methods is more sustainable. The paper also includes a large section on process methodology.

2

Improving machining performance against regenerative tool chatter through adaptive normal pressure at the tool clamping interface

Fu Q., Rashid A., Nicolescu C. M.

Journal of Machine Engineering

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2013

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Vol. 13, No. 1

93--105

EN

Chatter in machining process is one of the common failures of a production line. For a cantilever tool, such as a boring bar, the rule of thumb requires the overhang length of the tool to be less than 4 times the diameter. The reason is because longer overhang will induce severe tool vibration in the form of chatter during machining. When a longer overhang than 4 times diameter is necessary for performing special machining operations, damping methods are needed to suppress tool chatter. One of the methods is the constrained layer damping method. Materials, such viscoelastic material, are applied in the vibration node regions of the structure to absorb the concentrated vibration strain energy and transform the mechanical energy to heat. With a cantilever tool clamped in a tool holder, the clamping interface is usually the vibration node region. The friction in the joint interface with low normal pressure became another source of damping and can be used for tool chatter suppression in mechanical structures. Joint interfaces are well known to possess normal pressure dependent stiffness and damping. The normal pressure's effect on the structures frequency response function had been observed by H. Akesson [1] et al, and L.Mi [2] et al. However, the direct effect of the joint interface normal pressure on machining process stability hasn't been investigated. In this paper, a cantilever tool with 6,5 overhang length to diameter ratio is investigated. The direct effect of the tool clamping interface's normal pressure on the machining process stability is studied. Three different levels of clamping normal pressure are tested with an internal turning process. The machining results indicate another adaptable solution on shop floor for suppressing tool chatter.

3

Experimental analysis of a machining system with adaptive dynamic stiffness

Frangoudis C., Nicolescu C. M., Rashid A.

Journal of Machine Engineering

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2013

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Vol. 13, No. 1

49--63

EN

A main consideration in the operation of machine tools is vibrations occurring during the cutting process. Whether they are forced vibrations or self-excited ones, they have pronounced effects on surface quality, tool life and material removal rate. This work is an experimental study of interactions between natural characteristics, control parameters and process parameters of a machining system designed with adaptive dynamic stiffness. In order to comprehend these interactions, the effect of changes in dynamic stiffness on the system's response is examined. The system under study consists of an end-milling tool, a steel workpiece and a work holding device with controllable stiffness. Natural dynamic characteristics of the system components are determined through modal impact testing. Then the behaviour of the whole machining system is examined under both high and low cutting speed conditions by analysing vibration levels using acceleration signals acquired through a tri-axial sensor mounted on the workpiece. Cutting is performed in both directions of the horizontal plane of a CNC milling machine. In both cases the results are presented for two extremes of stiffness and damping in the work holding device. The effect of control parameters on the system's natural characteristics could be identified together with a relation between these parameters and the system's response in high and low cutting speed conditions. The high-damping configuration reduces the vibration amplitudes significantly, while the increase of pre-stress has a different effect depending on the cutting conditions.

4

Evaluation and representation of machine tool deformations

Archenti A., Osterlind T., Nicolescu C. M.

Journal of Machine Engineering

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2011

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Vol. 11, No. 4

105--117

EN

This paper presents a novel test concept for the evaluation of the accuracy of NC machine tools. The evaluation of machine tools deformations is performed by help of a device similar to the double ball bar (DBB) with the difference that an adjustable load generated by the devic can be applied between spindle nose and machine tool table. This load eliminates the play existing in machine tool joints, thus reproducing the testing conditions that exist during machining. Collected data are used to plot diagrams displaying characteristic aspects of machine tool performance and a number of key figures such as static stiffness may be determined. The data can also be used for trend analysis; to predict any accuracy deviations, and further to conduct preventive maintenance instead of emergency calls. The determined static behaviour could also be used to improve digital models for process simulations and compensation of errors that are caused by deflection.

5

Active alignment chuck for ultra-precision machining

Daghini L., Archenti A., Rashid A., Nicolescu C. M.

Journal of Machine Engineering

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2011

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Vol. 11, No. 4

39--48

EN

Ultraprecision (UP) components have become common in everyday life products such as mobile phones or compact high resolution digital cameras. Thus the need of producing such components with high accuracy and low production cost. UP machine tools are capable of extremely high accuracy in tool positioning but still today the workpiece is positioned by hand, hence the high production cost of UP components. A fully automated chain of production has been developed within the EU-IP project "Production 4 micro". This paper describes the active alignment chuck for workholding in UP machining. The chuck has been provided with a high damping interface (HDI) and to evaluate its efficiency the chuck has undergone an experimenta modal analysis (EMA) as well as machining tests. The chosen operation was grooving by fly cutting using a diamond tool. The EMA showed that the HDI was effective for those modes where there was relative displacement between one side and the other of the HDI. This result was confirmed by the machining tests as well. The HDI resulted being effective in damping high frequency modes (around 4 - 5 kHz), hence one expected benefit would be a longer tool life.

6

Design and dynamic characterization of composite material dampers for parting-off tools

Daghini L., Archenti A., Nicolescu C. M.

Journal of Machine Engineering

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2010

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Vol. 10, No. 2

57--70

EN

This paper introduces a novel design for parting-off tools and the method to characterize their performance. The principle followed in the design phase was to enhance the damping capability minimizing the loss in static stiffness through implementation of composite material interfaces. The tool has been characterized by the dynamic characteristics criterion, i.e. frequency and damping ratio, of the machining system, as well as the roughness of the machined surface criterion. This paper demonstrates a new model-based method for characterizing the machining system dynamic properties, applied, in this sThe presented mathematical model of the machining system is based on the data recorded by a microphone during operational conditions. In this way, a step beyond the classical method of analyzing the dynamics of a machining system, which separately identifies the structural and process parameters is taken. The analyses together with the experimental results proved that the parting-off tool was able to machine over a wide range of cutting parameters. It was found that the limiting factor for increasing cutting parameters is not the damping capability of the tool but the tool clamping system stiffness and the workholding system dynamic properties. This implies that, in order to further optimize the machining performance, it is vital to take consideration not only the tool-clamp-turret system but the whole machining system.