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The Influence of Workpiece Hardness on Plate Temperature during One Side Lapping
PublikacjaLapping leads to a surface with low roughness and high precision. Because of required parts accuracy tool flatness is the key to the successful machining. To avoid its excessive thermal expansion, plate temperature research was taken. The goal was to determine the correlation between the basic lapping conditions and wheel temperature. In work Bulsara et al. authors developed model to estimate the maximum and average temperature...
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Thermal and technological aspects of double face grinding of C45 carbon steel
PublikacjaIn grinding, the contact zone temperature is a decisive factor influencing the achievable surface quality and the grinding tool wear. In contrast to other grinding processes, only few information regarding double face grinding with planetary kinematics when processing steel is known up to date. Since the successive substitution of in-dustrial double-sided lapping processes by double-sided grinding, it has become necessary to the...
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Curve Curvature Analysis of a Grain Trajectories in Variable Honing of Cylindrical Holes of Thin Wall Cylinder Liners as a Honing Process Optimization Strategy
PublikacjaThe main problem of honing of thin wall cylinder liners is a thermal distortion of honed holes. The higher the value of the temperature of the honed workpiece, the greater its holes deformation. The paper presents a method of reducing the temperature occurring in the honing process as a result of the application of a variable honing kinematics conditions with particular emphasis on the analysis of the effect of the value of the...
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NUMERICAL SIMULATIONS OF HONING PROCESS OF THIN WALL CYLINDER LINERS, WITH CONSTANT AND WITH VARIABLE THICKNESS OF WALL OF HONED PARTS
PublikacjaNumerical simulations of honing process of thin-wall cylinder liners, with constant and with variable thickness of the wall of honed workpieces can improve and can help to conduct the experimental research of honing process and can improve the honing process. A very valuable research assumption, before performing the numerical analysis of computer simulation of honing process, is the measurement of the real geometry of the honing...
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Thermal and technological aspects of double face grinding of Al2O3 ceramic materials
PublikacjaDouble face grinding with planetary kinematics is a process to manufacture workpieces with plan parallel functional surfaces, such as bearing rings or sealing shims. In order to increase the economic efficiency of this process, it has to be advanced permanently. The temperature in the contact zone of most grinding processes has a huge influence on the process efficiency and the workpiece qualities. In contrast to most grinding...
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The Proposition of an Automated Honing Cell with Advanced Monitoring
PublikacjaHoning of holes allows for small shape deviation and a low value of a roughness profile parameter, e.g., Ra parameter. The honing process heats the workpiece and raises its temperature. The increase in temperature causes thermal deformations of the honed holes. The article proposes the construction of a honing cell, containing in addition to CNC honing machine: thermographic camera, sound intensity meter, and software for collecting...
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Investigation of the Effects of Tool Positioning Factors on Peak Temperature in Dissimilar Friction Stir Welding of AA6061-T6 and AA7075-T6 Aluminum Alloys
PublikacjaAmong the emerging new welding techniques, friction stir welding (FSW) is used frequently for welding high-strength aluminum alloys that are difficult to weld by conventional fusion-welding techniques. This paper investigated the effects of tool-positioning factors on the maximum temperature generated in the dissimilar FSW joint of AA6061-T6 and AA7075-T6 aluminum alloys. Three factors of plunge depth, tool offset, and tilt angle...
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Shaping of the workpiece surface in single-disc lapping
PublikacjaShape errors of the tool exert a dominant influence on the shape accuracy of the workpiece. The correlation between flatness errors of the lap and flatness errors of the workpieces was checked experimentally and determined analytically. Computer model of the workpiece shaping by lapping was developed. Evaluation method of the workpiece orientation as well as some simulation results for a lap with shape errors of convexity and cincavity...
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Vibration surveillance for efficient milling of flexible details fixed in adjustable stiffness holder
PublikacjaThe paper presents the results of research related to the possibility of using an intelligent workpiece holder with adjustable stiffness, during end milling process. Machining a one side supported flexible workpiece will be performed with constant spindle speed and feed speed. In order to avoid hazardous vibration, stiffness of the especially designed spring (mounted in a workpiece holder) will be modified off-line. In order to...
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The clamping selection method to reduce the vibration of large-size workpieces during the face milling process
PublikacjaThe article introduces a method for selecting the best clamping conditions to obtain vibration reduction during milling of large-size workpiece. It is based on experimental modal analysis performed for a set of assumed, fixing conditions of a considered workpiece to identify Frequency Response Functions (FRFs) for each tightening torque of the mounting screws. Simulated plots of periodically changing nominal cutting forces are...
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Experimentally Aided Operational Virtual Prototyping to Predict Best Clamping Conditions for Face Milling of Large-Size Structures
PublikacjaVibrations occurring during milling operations are one of the main issues disturbing the pursuit of better efficiency of milling operations and product quality. Even in the case of a stable cutting process, vibration reduction is still an important goal. One of the possible solutions to obtain it is selection of the favorable conditions for clamping the workpiece to the machine table. In this paper, a method for predicting and...
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Adjusting the Stiffness of Supports during Milling of a Large-Size Workpiece Using the Salp Swarm Algorithm
PublikacjaThis paper concerns the problem of vibration reduction during milling. For this purpose, it is proposed that the standard supports of the workpiece be replaced with adjustable stiffness supports. This affects the modal parameters of the whole system, i.e., object and its supports, which is essential from the point of view of the relative tool–workpiece vibrations. To reduce the vibration level during milling, it is necessary to...
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Vibration Surveillance System with Variable Stiffness Holder for Milling Flexible Details
PublikacjaEfficient milling of the flexible details (i.e. rotor blades, thin-walled elements) using slender ball-end tools is a difficult task due to possibility of vibration occurrence. Because of the existence of certain conditions (small depths of cutting, regeneration phenomena), cutting process may lose stability and self-excited chatter vibration may appear. Frequency of the chatter vibration is close to dominant natural frequency...
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Optimization of clamping stiffness during milling of high-dimensional structures with the use of techniques of experiment – aided virtual prototyping
PublikacjaThe subject of this paper is a method of searching for conditions of minimizing the vibration level of a tool-high dimensional flexible workpiece, at unchangeable technological parameters of the machining process. It depends on repeatable change of the values of the stiffness coefficients as soon as an optimal vibration state of the workpiece approaches. There are assessed the values of dominant ”peaks” in the frequency spectra...
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Modelling and Simulation of a New Variable Stiffness Holder for Milling of Flexible Details
PublikacjaModern industry expectations in terms of milling operations often demand the milling of the flexible details by using slender ball-end tools. This is a difficult task because of possible vibration occurrence. Due to existence of certain conditions (small depths of cutting, regeneration phenomena), cutting process may become unstable and self-excited chatter vibration may appear. Frequency of the chatter vibration is close to dominant...
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Surface irregularities as a complex signal of tool representation together with uneven displacement in respect to the workpiece
PublikacjaIn a dynamic machining process, distortion in surface irregularity is a very complex phenomenon. Surface irregularities form a periodic representation of the tool profile with various kinds of disturbance in a broad range of changes in the height and length of the profile. To discern these irregularity disturbances, interactions of the tool in the form of changes perpendicular and parallel relative to the workpiece were analyzed...
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Results after grinding C45 steel
Dane BadawczeThe database contains results from nanoindenter, scanning microscope and also X-ray diffractometer. To determine the residual stresses and the size of the crystallites in the ferrite grains in the grinded surface layer, the Williamson Hall analysis of the X-ray diffraction patterns was performed. XRD diffraction patterns were also used to perform a...
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A method of predicting the best conditions for large-size workpiece clamping to reduce vibration in the face milling process
PublikacjaThe paper presents an innovative method of solving the problem of vibration suppression during milling of large-size details. It consists in searching for the best conditions for clamping the workpiece based on a rapid modal identification of the dominant natural frequencies only and requires repetitive changes in the tightening torque of the clamping screws. Then, by estimating the minimum work of the cutting forces acting in...
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An Analysis of Uncertainty and Robustness of Waterjet Machine Positioning Vision System
PublikacjaThe paper presents a new Automatic Waterjet Positioning Vision System (AWPVS) and investigates components of workpiece positioning accuracy. The main purpose of AWPVS is to precisely identify the position and rotation of a workpiece placed on a waterjet machine table. Two webcams form a basis for the system, and constitute its characteristics. The proposed algorithm comprises various image processing techniques to assure a required...
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Influence and development of new kinematic systems in flat surface lapping
PublikacjaThe face grinding and lapping technology is widely used in the field of the precise and ultraprecise manufacturing. It has become an indispensable technology in the manufacture of many parts. An absence of material restrictions allows machining both metal and non-metallic materials, including technical ceramics [1]. Nowadays there are mainly two kinematic systems in lapping machines [2]. The machining plane-parallel surfaces is...
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Minimization of vibrations during milling of flexible structures using mechatronic design techniques
PublikacjaThe paper presents an innovative effective method of minimizing vibrations during milling of flexible structures, using a new vibration suppression method based on a workpiece holder with adjustable support stiffness. The proposed method is rooted in mechatronic design techniques, which can become a standard procedure for optimizing the milling process.
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Microgrinding with single-disk lapping kinematics.
PublikacjaGrinding operations are carried out with a variety of tool-workpiece configurations. The selection of a grinding process for a particular application depends on part shape, part size, ease of fixture, requirements concerning the acceptable shape errors. It is evident that lapping is very effective in eliminating the waviness while surface grinding is not. Dual disk machines for the double face grinding with planetary kinematics...
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An Experimentally Aided Operational Virtual Prototyping to Obtain the Best Spindle Speed during Face Milling of Large-Size Structures
PublikacjaAbstract: The paper presents an original method concerning the problem of vibration reduction in the general case while milling large-size and geometrically complex details with the use of an innovative approach to the selection of spindle speed. A computational model is obtained by applying the so-called operational approach to identify the parameters of the workpiece modal model. Thanks to the experimental modal analysis results,...
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Optimal spindle speed determination for vibration reduction during ball-end milling of flexible details
PublikacjaIn the paper a method of optimal spindle speed determination for vibration reduction during ball-end milling of flexible details is proposed. In order to reduce vibration level, an original procedure of the spindle speed optimisation, based on the Liao–Young criterion, is suggested. As the result, an optimal, constant spindle speed value is determined. For this purpose, on-stationary computational model of machining process is...
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A technique of experiment aided virtual prototyping to obtain the best spindle speed during face milling of large-size structures
PublikacjaThe paper presents an original method concerning vibration suppression problem during milling of large-size and geometrically complicated workpieces with the use of novel way of selecting the spindle speed. This consists in repetitive simulations of the cutting process for subsequent values of the spindle speed, until the best vibration state of the workpiece is reached. An appropriate method of obtaining a computational model,...
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An Improved Method of Minimizing Tool Vibration during Boring Holes in Large-Size Structures
PublikacjaThe paper presents a thoroughly modified method of solving the problem of vibration suppression when boring large-diameter holes in large-size workpieces. A new approach of adjusting the rotational speed of a boring tool is proposed which concerns the selection of the spindle speed in accordance with the results of the simulation of the cutting process. This streamlined method focuses on phenomenological aspects and involves the...
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Economical wood sawing with circular saw blades
PublikacjaMaterial- and energy-saving belong to the basic requirements which are imposed on the contemporary manufacturing processes. Since realization of those processes gives measurable profits not only economical but also ecological. In case of wood sawing with circular saw blades material- and energy-savings are dependent on total overall set of teeth (theoretical kerf) and teeth position accuracy in relation to the workpiece. Hence,...
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The Method of Finding the Optimal Spindle Speed When Milling Flexible Details
PublikacjaThe paper presents a new method of vibration reduction during milling of flexible details. The method consists in selecting the optimal spindle speed, based on the natural frequency of the workpiece. For this purpose, an original method was created, which is based on minimizing the work of cutting forces in the direction of the depth of cutting. The effectiveness of the method has been proved by comparing the RMS values of vibration...
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New kinematic systems in single-sided lapping and their influence on lap wear
PublikacjaPrevious studies on one-sided lapping allow to state that not only parameters of lapping elements (i.e. properties of workpiece, abrasive grains and lapping plate) impact on a lapping efficiency. Influential are also kinematics and dynamics of the process. It is crucial to control an average velocity of lapping (v), a distribution of tangential acceleration (at), a nominal pressure (p), a lapping time (t) and disposal of workpiece...
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High Speed Milling vibration surveillance with optimal spindle speed based on optimal speeds map
PublikacjaThe paper presents the method of the surveillance of the self-excited chatter vibration. At first, the workpiece modal parameters are estimated based on experimental data which leads to verification of computational model. Then, for selected surface points optimal spindle speeds are calculated. By considering sufficient amount of points it is possible to build a map of optimal spindle speeds. Experimental results show that this...
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Monitoring of single-side lap grinding with electroplated tools
PublikacjaThe results presented in the paper show that utilising microphones as audible sound sensors is a suitable approach for monitoring a single-side lap grinding process due to the low levels of noise generated by the drives of a machine tool. The results confirm that sound signal analysis is a feasible and relatively simple method to monitor a lap grinding process with the use of an audible sound sensor. Proposed method can be used...
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Economical wood sawing with circular saw blades of a new design (Ekonomicno piljenje drva kruznom pilom novog dezajna)
PublikacjaMaterial-saving and energy-saving belong to the basic requirements imposed on contemporary manufacturing processes. The realization of these processes gives measurable profi ts, not only economical butalso ecological. In the case of wood sawing with circular saw blades, material- and energy-savings are dependent on total overall set of teeth (theoretical kerf) and teeth position accuracy in relation to the workpiece. Hence, it...
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VIBRATION SURVEILLANCE DURING MILLING OF FLEXIBLE DETAILS WITH A USE OF THE ACTIVE OPTIMAL CONTROL
PublikacjaThe main goal of modern machining operations is to achieve increasingly better performance. High Speed Machining and/or High Performance Cutting, despite a lot of advantages, have also some drawbacks, for example, a possibility of losing stability and development of self-excited chatter vibration. This paper presents an approach of vibration surveillance during high speed milling with a use of active optimal control. Non-stationary...
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Optimization of the spindle speed during milling of large-sized structures with the use of technique of Experiment-Aided Virtual Prototyping
PublikacjaIn the paper are presented considerations concerning vibration suppression problems during milling of large-sized workpieces with the use of innovative method of matching the spindle speed of cutting tool. It depends on repeatable change of the spindle speed value as soon as the optimal vibration state of the workpiece approaches. The values of dominant “peaks” in the frequency spectra and the Root Mean Square (RMS) values of time...
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Profile irregularities of turned surfaces as a result of machine tool interactions
PublikacjaThe paper describes the influence of the machining operation on a surface, which disturbs the projection of the tool profile in the form of its relative movements with respect to the object. The elements of the machine tool undergo constant wear during the machining process, it is therefore important to recognize the effects of their influence on the surface's irregularities. Amplitude-frequency analysis of lateral profiles has...
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THE EFFECT OF ALTERNATIVE CUTTER PATHS ON FLATNESS DEVIATIONS IN THE FACE MILLING OF ALUMINUM PLATE PARTS
PublikacjaIn this paper the relationships between the alternative machining paths and flatness deviations of the aluminum plate part, were presented. The flatness tolerance of the main surface of the plate part has crucial meaning due to the assembly requirement of piezoelectric elements on the radiator. The aluminum bodies under investigation are the base part of the radiators with crimped feathers for the train industry. The surface of...
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Selected aspects of the surface quality of the wooden elements after planing
PublikacjaThe quality of the surface of wooden elements, that have been planed, has got a crucial meaning in the whole production process flow, since the obtained effects affect the quality of wooden surface after painting. The emergence of defects in most cases causes need to qualify workpiece as a scrap part or additional work activity must be done. In the paper selected results of the investigation of the effect of the cutting tool wear...
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Fracture Toughness and Shear Yield Strength Determination for Two Selected Species of Central European Provenance
PublikacjaWhen offcut of wood is formed by shearing, Atkins’s analyses of sawing processes can be applied. Using this modern approach, it is possible to determine the fracture toughness and shear yield strength of wood. This model is only applicable for the axial-perpendicular cutting direction because both of these parameters are suitable for the given direction of cutting edge movement and cannot be considered material constants. Alternatively,...
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An innovative approach to the forecasting of energetic effects while wood sawing
PublikacjaIn the classical approach, energetic effects (cutting forces and cutting power) of wood sawing process are generally calculated on the basis of the specific cutting resistance, which is in the case of wood cutting the function of more or less important factors. On the other hand, the cutting forces (power) problem may be tackled with an innovative, up-to-date fundamental analysis of the mechanics of sawing based on modern fracture...
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An Innovative Approach to the Forecasting of Energetic Effects While Wood Sawing
PublikacjaIn the classical approach, energetic effects (cutting forces and cutting power) of wood sawing process are generally calculated on the basis of the specifi c cutting resistance, which is in the case of wood cutting the function of more or less important factors. On the other hand, the cutting forces (power) problem may be tackled with an innovative, up-to-date fundamental analysis of the mechanics of sawing based on modern fracture mechanics....
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Multi-criteria Robot Selection Problem for an Automated Single-Sided Lapping System
PublikacjaFlat lapping is a crucial process in a number of precision manufacturing technologies. Its aim is to achieve extremely high flatness of the workpiece. Single-sided lapping machines have usually standard kinematic systems and are used in conjunction with conditioning rings, which are set properly be-tween the center and the periphery of the lapping plate. In this paper, instead of conventional single-side lapping machine, an automated...
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Comparison of Surface Quality and Tool-Life of Glulam Window Elements after Planing
PublikacjaThe quality of the surface of wooden elements, that have been planed, has a crucial importance in the whole production process, since the obtained effects affect the quality of wooden surface after fi nishing (painting). The occurrence of defects is usually the reason for qualifying a workpiece as scrap or for requiring additional work. This paper presents the selected results of research of the effect of the cutting tool wear...
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A Critical Reanalysis of Uncontrollable Washboarding Phenomenon in Metal Band Sawing
PublikacjaThe article analyzes the cutting process of hard bars. Investigations conducted in industrial conditions demonstrated the presence of surface errors in the machined workpieces in the form of washboard patterns. The purpose of this study was to analyze the results of cutting on band sawing machines with different band saw blades. The cutting processes were conducted on three different horizontal band sawing machine types. Analyzed...
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Vascular stents - materials and manufacturing technologies
PublikacjaThe objective of this article is to present materials and technology for the manufacture of vascular stents with appropriate design requirements. The use of the right material is very important in implantology. A biomaterial introduced into the circulatory system must be biocompatible and hemocompatible. At the same time, it should not initiate toxic, mutagenic, or immunological reactions. Currently, 316L stainless steel (316L...
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Surface Texture after Turning for Various Workpiece Rigidities
PublikacjaIn the paper, we present an analysis of the surface texture of turned parts with L/D (length/diameter) ratios of 6 and 12 and various rigidity values. The studies were carried out on samples made of S355JR steel and AISI 304 stainless steel. A detailed analysis of 2D surface profiles was carried out by using a large number of parameters that allowed us to distinguish significant differences in the surface microgeometry, which confirmed...
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Modeling of lapping plate wear and conditioning in single-sided lapping
PublikacjaIn order to achieve higher quality on worked surfaces with lower roughness, very high accuracy of shape and dimensions it is crucial to improve conventional finishing technologies and to develop new working principles. Single-sided lapping is one of the most effective planarization technologies and it is determined by a number of factors and boundary conditions. The most significant influence over a dimensional and profile accuracy,...
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Machining process sequencing and machine assignment in generative feature-based CAPP for mill-turn parts
PublikacjaProcess selection and sequencing, as one of the most complex issues when evaluated from a mathematical point of view and crucial in CAPP, still attract research attention. For the current trend of intelligent manufacturing, machining features (MFs) are the information carriers for workpiece geometry and topology representation. They are basically derived from CAD models and are used by downstream engineering applications. A feature-based...
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The use of Preston equation to determine material removal during lap-grinding with electroplated CBN tools
PublikacjaGrinding executed in a lapping configuration is an alternative finishing process benefiting from both grinding and free-abrasive machining, while minimizing the heat effect impact. Electroplated tools can be effectively used in different abrasive processes, including high-speed grinding, however, the assessment of machining performance over time is a key factor in their correct use to achieve satisfactory technological results....