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Research Papers

High-Definition Metrology Enabled Surface Variation Control by Cutting Load Balancing1

[+] Author and Article Information
Hai Trong Nguyen

Department of Material Cutting and
Industrial Instrument,
Hanoi University of Science and Technology,
Hanoi, Vietnam

Hui Wang

Department of Industrial and
Manufacturing Engineering,
Florida State University,
Tallahassee, FL 32310;
Department of Mechanical Engineering,
University of Michigan,
Ann Arbor, MI 48109

Bruce L. Tai

Department of Mechanical Engineering,
Texas A&M University,
College Station, TX 77843

Jie Ren

Department of Industrial and
Manufacturing Engineering,
Florida State University,
Tallahassee, FL 32310

S. Jack Hu, Albert Shih

Department of Mechanical Engineering,
University of Michigan,
Ann Arbor, MI 48109

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received January 26, 2015; final manuscript received May 27, 2015; published online September 9, 2015. Assoc. Editor: Guillaume Fromentin.

J. Manuf. Sci. Eng 138(2), 021010 (Sep 09, 2015) (11 pages) Paper No: MANU-15-1062; doi: 10.1115/1.4030782 History: Received January 26, 2015

This paper presents a method to reduce surface variation in face milling processes based on high-definition metrology (HDM) measurements. Our previous research has found and established the relations between surface variation patterns, cutting forces, and process variables. Based on the findings, this paper compares potential machining methods and finds that the approaches of varying feed rate and lateral cutter path planning are most feasible for surface variation control. By combining the two approaches, an algorithm is developed to reduce cutting force variation along the feed direction and circumferential direction, respectively, thereby reducing the surface variation. The varying feed method can effectively eliminate the surface variation along the feed direction, while the optimal cutter path approach balances the cutting loads on the cutter and contributes to reducing cutting force variation along feed direction. Case studies were conducted based on a cutting experiment to demonstrate that the proposed method can improve the surface flatness by 25%. The cutter path adjustment algorithm was also implemented in an automotive engine plant leading to 15–25% improvement in surface flatness.

Copyright © 2016 by ASME
Topics: Stress , Cutting
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References

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Figures

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Fig. 1

(a) High-definition metrology data of an engine head [1] and (b) global trend of an engine head

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Fig. 4

Gouging due to the cutter adjustment in the vertical direction

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Fig. 5

The average axial force and arc length of toolmark on a sample workpiece [20]

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Fig. 6

(a) Cutting force diagram of face milling and (b) cutting load imbalance modeling

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Fig. 7

Machined surface when the spindle speed is changed

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Fig. 8

(a) Workpiece geometry and initial cutter position and (b) possible cutter path candidates to be explored by the pattern search method

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Fig. 9

Machined surfaces with symmetric geometry

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Fig. 10

Engineering heuristic approach to finding the optimal cutter path for cutting load balancing

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Fig. 11

(a) Asymmetric geometry of an engine deck face and (b) partition of workpiece surface into segments

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Fig. 12

A framework of HDM enabled surface variation control

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Fig. 13

Comparison between machined surfaces of constant feed rate and varying feed rate

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Fig. 14

Feed rate variation, stepwise feed rate, and compensated stepwise feed rate

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Fig. 15

(a) Original and the optimized cutter entry path for an in-plant study and (b) optimization results of the cutter entry path

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Fig. 16

(a) Solid aluminum block and the cutting area and (b) geometry of cutting area

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Fig. 17

(a) MRR produced by a straight cutter path, (b) MRR variation induced surface height, and (c) estimated global shape

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Fig. 18

Cutting load imbalance produced by a straight cutter path

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Fig. 19

Inclined surface due to cutting load imbalance (by a straight cutter path)

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Fig. 20

Optimized cutter path

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Fig. 21

Parameter ΔV (reflecting imbalance) along the feed direction of cutter path

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Fig. 22

Machined surface produced by the optimized cutter path with constant feed rate

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Fig. 23

Applying varying feed to the optimized cutter path

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Fig. 24

(a) Machined surface of the optimized cutter path with varying feed rate and (b) comparison of the surface height distributions for different cutter paths

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