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Process Stability Strategies in Milling of Thin-walled Inconel 718
University West, Department of Engineering Science, Division of Production Engineering. (PTW)
University West, Department of Engineering Science, Division of Production Engineering. (PTW)ORCID iD: 0000-0001-9331-7354
University West, Department of Engineering Science, Division of Production Engineering. (PTW)
University West, Department of Engineering Science, Division of Production Engineering. (PTW)ORCID iD: 0000-0003-1408-2249
2012 (English)In: The 4th Manufacturing engineering society international conference (MESIC 2011): 21–23 September 2011, Cadiz, Spain / [ed] M. Marcos, J. Salguero, American Institute of Physics (AIP), 2012, Vol. 1431, 465-472 p.Conference paper, Published paper (Refereed)
Abstract [en]

Trends in Aerospace development have led to thin-walled, reduced-weight engine designs. The demands in manufacturing have forced production speeds and material removal rates (MRR) to increase. 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 height 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 gives guidelines on how to accomplish robust machining practices. It also answers the following questions: How critical is the choice of offset between tool and workpiece during milling setup? And what effects do the entry and exit of cut have on system vibrations?

Place, publisher, year, edition, pages
American Institute of Physics (AIP), 2012. Vol. 1431, 465-472 p.
Series
AIP Conference Proceedings, ISSN 1551-7616 ; 1431/1
Keyword [en]
Thin-wall, Inconel 718, chatter, machining vibrations
National Category
Engineering and Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-4330DOI: 10.1063/1.4707597ISI: 000307644700054Scopus ID: 2-s2.0-84863327648ISBN: 978-0-7354-1017-6 (print)OAI: oai:DiVA.org:hv-4330DiVA: diva2:527437
Conference
The 4th Manufacturing engineering society international conference
Available from: 2012-05-31 Created: 2012-05-21 Last updated: 2016-11-21Bibliographically 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. 96 p.
Keyword
Milling, vibrations, chatter, stability, prediction, thin-wall, Inconel 718.
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-4955 (URN)978-91-7501-322-0 (ISBN)
Presentation
2012-12-07, KTH Royal Institute of Technolgy, Brinellvägen 68, Stockholm, 10:00 (English)
Opponent
Supervisors
Available from: 2012-12-28 Created: 2012-12-27 Last updated: 2015-10-02Bibliographically approved

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