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Milling strategies for thin-walled components
University West, Trollhättan, Sweden .
University West.
University West.
University West.
2012 (English)In: Advances In Materials Processing Technologies, Trans Tech Publications Inc., 2012, Vol. 498, 177-182 p.Conference paper, Published paper (Refereed)
Abstract [en]

Recent developments in the Aerospace industry have led to thin-walled, reduced-weight engine designs. Due to demands in manufacturing, production speeds and material removal rates (MRR) have increased. As component wall thickness gets thinner, the consequence oftentimes is an increase in chatter vibrations. This paper suggests that a correctly chosen tool-to-workpiece offset geometry may lead to a robust and chatter-free process. The results show the differences in force response for three geometries while varying the overhang of the workpiece. This is part of a concerted effort to develop a robust methodology for the prediction of chatter vibrations during milling operations of thin-walled Aerospace components. This paper outlines certain robust machining practices. It also analyzes the criticality of the choice of offset between tool and workpiece during milling setup as well as the effects that the entry and exit of cut have on system vibrations.

Place, publisher, year, edition, pages
Trans Tech Publications Inc., 2012. Vol. 498, 177-182 p.
Series
Advanced Materials Research, ISSN 1022-6680 ; 498
Keyword [en]
Thin-wall, Inconel 718, chatter, machining vibrations
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:kth:diva-105216DOI: 10.4028/www.scientific.net/AMR.498.177ISI: 000312878000030Scopus ID: 2-s2.0-84860254349ISBN: 978-3-03785-359-7 (print)OAI: oai:DiVA.org:kth-105216DiVA: diva2:570404
Conference
4th Manufacturing Engineering Society International Conference, MESIC 2011; Cadiz; Spain; 21 September 2011 through 23 September 2011
Note

QC 20121119

Available from: 2012-11-19 Created: 2012-11-19 Last updated: 2014-08-25Bibliographically approved
In thesis
1. Strategies for Reducing Vibrations during Milling of Thin-walled Components
Open this publication in new window or tab >>Strategies for Reducing Vibrations during Milling of Thin-walled Components
2012 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Factors such as environmental requirements and fuel efficiency have pushed aerospace industry to develop reduced-weight engine designs and thereby light-weight and thin-walled components. As component wall thickness gets thinner and the mechanical structures weaker, the structure becomes more sensitive for vibrations during milling operations. Demands on cost efficiency increase and new ways of improving milling operations must follow.

Historically, there have been two “schools” explaining vibrations in milling. One states that the entry angle in which the cutting insert hits the work piece is of greater importance than the exit angle. The other states that the way the cutter leaves the work piece is of greater importance than the cutter entry. In an effort to shed some light over this issue, a substantial amount of experiments were conducted. Evaluations were carried out using different tools, different tool-to-workpiece offset positions, and varying workpiece wall overhang. The resultant force, the force components, and system vibrations have been analyzed.

The first part of this work shows the differences in force behavior for three tool-to-workpiece geometries while varying the wall overhang of the workpiece. The second part studies the force behavior during the exit phase for five different tool-to-workpiece offset positions while the overhang is held constant. The workpiece alloy throughout this work is Inconel 718.

As a result of the project a spread sheet milling stability prediction model is developed and presented. It is based on available research in chatter theory and predicts the stability for a given set of variable input parameters.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2012. xii, 57, 23 p.
Series
Trita-IIP, ISSN 1650-1888 ; 12:03
Keyword
Milling, vibrations, chatter, stability, prediction, thin-wall, Inconel 718
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-107156 (URN)978-91-7501-322-0 (ISBN)
Presentation
2012-12-07, Sal M311, Brinellvägen 68, KTH, Stockholm, 10:00 (Swedish)
Opponent
Supervisors
Note

QC 20121206

Available from: 2012-12-06 Created: 2012-12-06 Last updated: 2012-12-10Bibliographically approved

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CiteExportLink to record
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Citation style
  • apa
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Output format
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