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Production Engineer | Injection Moulding Specialist | Manufacturing Excellence | Lean Six Sigma | Team Leadership As a Production Engineer at Ganesh Gouri Industries Pvt Ltd, I bring extensive expertise in inj. moulding
RECENT METHODS FOR OPTIMIZATION OF PLASTIC INJECTION MOLDING PROCESS –A RETROSPECTIVE AND LITERATURE REVIEW
International Journal of Engineering Science and Technology
Vol. 2(9), 2010, 4540-4554
P.K. Bharti
Assistant professor, Mechanical Engineering Department, Integral
University, Lucknow, 226023, India
M. I. Khan
Prof. and Head, Mechanical Engineering Department, Integral University, Lucknow, 226023, India
Harbinder Singh
Professor and Director, Bundel khand Institute of Engineering and Technology, Jhansi, India
Abstract:
Injection molding has been a challenging process for many manufacturers and researchers to produce products meeting requirements at the lowest cost. Faced with global competition in injection molding industry, using the trialand-error approach to determine the process parameters for injection molding is no longer good enough. Factors that affect the quality of a molded part can be classified into four categories: part design, mold design, machine performance and processing conditions. The part and mold design are assumed as established and fixed. During production, quality characteristics may deviate due to drifting or shifting of processing conditions caused by machine wear, environmental change or operator fatigue.
Determining optimal process parameter settings critically influences productivity, quality, and cost of production in the plastic injection molding (PIM) industry. Previously, production engineers used either trial-and-error method or Taguchi’s parameter design method to determine optimal process parameter settings for PIM. However, these methods are unsuitable in present PIM because of the increasing complexity of product design and the requirement of multi-response quality characteristics.
This article aims to review the recent research in designing and determining process parameters of injection molding. A number of research works based on various approaches have been performed in the domain of the parameter setting for injection molding. These approaches, including mathematical models, Taguchi method, Artificial Neural Networks (ANN),Fuzzy logic, Case Based Reasoning (CBR), Genetic Algorithms (GA), Finite Element Method(FEM),Non Linear Modeling, Response Surface Methodology, Linear Regression Analysis ,Grey Rational Analysis and Principle Component Analysis (PCA) are described in this article. The strength and the weakness of individual approaches are discussed. It is then followed by conclusions and discussions of the potential research in determining process parameters for injection molding
I now feel production planning and control is a component of process chart analysis as far as process improvement is concerned. Industrial engineers have to improve production planning routines as part of process chart analysis. Such an emphasis is not there in IE curriculum, as process chart is method is taught in work study or time and motion study courses.
Product - Part Production Processes - Miscellaneous Items - Collection
DESIGNING & MANUFACTURING OF SPLIT CAVITY TWO PLATE INJECTION MOULD FOR GAS CAP
April 30, 2018
SYNOPSIS
Any product to be manufactured invariably requires tools, tool design and development and planning. Tool is an aid for mass production it should be accurate & economical for achieving good quality products at lesser cost. The economy & life of moulds entirely rests on the designer & his role is very important. This project work incorporates the details of designing process planning & manufacturing Injection mould for GAS CAP. This project incorporates the literal survey of plastic material properties plastic moulding, steel is used in mould making functional aspects of component & various aspects such as feed system ejection of the comp. Parting surface, cooling of mould various consideration, where done prior to actual design of mould.
The process planning for manufacture & electrode planning of cavities required for mould & assembling tryout & trouble shooting is given.
1.1Dimensioning Dimensioning from datum
1.2 Redundant dimensioning
1.3 Stackup of tolerances by arithmetic method
1.4 Geometric tolerances
1.5 Geometric tolerances interpretation
1.6 Surface roughness
1.6.1 Definition of surface finish methods
2.Production Drawing Tolerances
Process planners have to understand the functional requirements of the design and can suggest design changes that make production easy and economical.
2.1 Tolerancing in production
Any dimension and its surface finish are not achieved in one production operation. Therefore, each production operation are to be specified with a tolerance such that the sum of all the tolerance results in the tolerance specified for the component at the end of the final operation.
2.1.1 Process to meet geometric tolerances
Causes of geometric deviations
1. Fixturing: Multiple fixturing increases deviations.
2. Machine accuracy and rigidity
3. Tool accuracy
4. Tool deflection
5. Cutting temperature
6. Vibrations in machine tool and cutting tool
7. Material heterogeneities
8. Kinematics
Hence careful choice and combination of machine tools, cutting conditions, tooling and fixtures and production operation level of tolerance strategies are required to achieve the tolerances specified in component drawing.
2.1.2 Production tolerancing
2.2 Tolerances in forming operations
3 Short Review of Statistical Tolerancing
3.1 Process Capability
1 Drawing Basics of Engineering Drawings - Reading Drawings ___________
For the dimensions of parts that would assemble, the dimensioning should originate at a datum. The datum is indicated in the drawing.
1.2 Redundant dimensioning
In a given direction, a surface should be indicated by one and only dimension.
_____________
_____________
_____________
_____________
1.3 Stackup of tolerances by arithmetic method
For examples in case of step turning with multiple steps, the interval tolerance of the result is equal to the sum of the tolerances of the components in length.
1.4 Geometric tolerances
The geometrical tolerances of form and positions are defined in the ISO standard for Tolerances for Form and Position (ISO Standard 111, 1983)
Process planners have to understand the functional requirements of the design and can suggest design changes that make production easy and economical.
2.1 Tolerancing in production
Any dimension and its surface finish are not achieved in one production operation. Therefore, each production operation are to be specified with a tolerance such that the sum of all the tolerance results in the tolerance specified for the component at the end of the final operation.
2.1.1 Process to meet geometric tolerances
Causes of geometric deviations
1. Fixturing: Multiple fixturing increases deviations.
2. Machine accuracy and rigidity
3. Tool accuracy
4. Tool deflection
5. Cutting temperature
6. Vibrations in machine tool and cutting tool
7. Material heterogeneities
8. Kinematics
Hence careful choice and combination of machine tools, cutting conditions, tooling and fixtures and production operation level of tolerance strategies are required to achieve the tolerances specified in component drawing.
2.1.2 Production tolerancing - Feasibility
Halevi gave the example of set up with fixture repeatability of 0.1 mm and the machine accuracy of 0.02 mm. When the counterbore is made this machine and fixture, the length of the internal minor diameter will come 20 + or - 0.04. It is acceptable because the required dimension is 20 + or - 0.1 mm.
The total length of the work piece is 70 mm, minor bore is 20 mm and counter bore length is 30 mm. So the length of the uncut portion is 20 mm and with this present errors it will come out to be 20 + or - 0.14. Acceptable because required dimension is 20 + or - 0.15.
But if machine accuracy is 0.03 mm, the resulting dimension tolerance will be 20 + or - 0.16. Not acceptable. Hence it is important to know the error quantities and see whether the machine and accessories in combination can produce the part to the specification or not.
2.2 Tolerances in forming operations
Halevi has given the example of a die working on a sheet metal blank. He says errors or tolerances achieved are of three types.
1. Tool dependent dimensions.
2. non-tool-dependent and
3. non-tool dependent dimensions in the direction of the closing the tool (travel of the punch).
Machine accuracy is estimated by type three errors. Improvement of machine accuracy and jigs and fixtures will minimize type 2 errors. Tool accuracy has to be improved for type 1 errors.
3 Short Review of Statistical Tolerancing
3.1 Process Capability
Productivity Improvement Through Machining Time Reduction and Machining Cost Reduction - Important Industrial Engineering Task.
Process improvement - What is machine time reduction? Man time reduction? Material usage reduction? Energy reduction? Information cost reduction?
The first president of ASME in his inaugural presidential address exhorted mechanical engineers to attention to the cost of reduction of machines and items produced through mechanical engineering design and production processes like cars.
The genius in F.W. Taylor resulted in proposing productivity improvement through machining time reduction (machine time reduction) and man time reduction as the core activity which will give cost reduction and income increase (to both employees and companies, this labor and capital).
Machining time reduction can be achieved by improving each of the elements that are used in machining. Taylor investigated each machine element - machine tools for power and rigidity, tool materials and tool geometry, work holding, use of coolant, cutting parameters (cutting speed, feed, depth of cut) and developed data and science for each element and increased productivity of machining. The framework laid by Taylor is followed even today and productivity improvement of machining is occurring.
TAYLOR (1906) - ELEMENTS AFFECTING CUTTING SPEED OF TOOLS IN THE ORDER OF THEIR RELATIVE IMPORTANCE
278 The cutting speed of a tool is directly dependent upon the following elements. The order in which the elements are given indicates their relative effect in modifying the cutting speed, and in order to compare them, we have written in each case ๏ฌgures which represent, broadly speaking, the ratio between the lower and higher limits of speed as affected by each element. These limits will be met with daily in machine shop practice.
279 (A) The quality of the metal which is to be cut; i.e., its hardness or other qualities which affect the cutting speed.
Proportion is as 1 in the case of semi-hardened steel or chilled iron to 100 in the case of very soft low carbon steel.
280 (B) The chemical composition of the steel from which the cutting tool is made, and the heat treatment of the tool.
Proportion is as 1 in tools made from tempered carbon steel to 7 in the best high speed tools.
281 (C) The thickness of the shaving; or, the thickness of the spiral strip or band of metal which is to be removed by the tool, measured while the metal retains its original density; not the thickness of the actual shaving, the metal of which has become partly disintegrated.
Proportion is as 1 with thickness of shaving 3/16 of an inch to 3.5 with thickness of shaving 1/64 of an inch.
282 (D) The shape or contour of the cutting edge of the tool, chie๏ฌy because of the effect which it has upon the thickness of the shaving.
Proportion is as 1 in a thread tool to 6 in a broad nosed cutting tool. ,
283 (E) Whether a copious stream of water or other cooling medium is used on the tool.
Proportion is as 1 for tool running dry to 1.41 for tool cooled by a copious stream of water.
284 (F) The depth of the cut; or, one-half of the amount by which the forging or casting is being reduced in diameter in turning.
Proportion is as 1 with 1/2 inch depth of cut to 1.36 with 1/8 inch depth of cut.
285 (G) The duration of the cut; i. c., the time which a tool must last under pressure of the shaving without being reground.
Proportion is as 1 when tool is to be ground every 1.5 hour to 1.207 when tool is to be ground every 20 minutes.
286 (H) The lip and clearance angles of the tool.
Proportion is as 1 with lip angle of 68 degrees to 1.023 with lip angle of 61 degrees.
287 (J) The elasticity of the work and of the tool on account of producing chatter.
Proportion is as 1 with tool chattering to 1.15 with tool running smoothly.
288 A brief recapitulation of these elements is as follows:
(A) quality of metal to be cut: 1 to 100;
(B) chemical composition of tool steel: 1 to 7;
(C) thickness of shaving: 1 to 3.5;
(D) shape or contour of cutting edge: 1 to 6;
(E) copious stream of water on the tool: 1 to 1.41;
(F) depth of cut: 1 with 1/2 inch depth to 1.36 with 1/8 inch depth of cut;
(G) duration of cut: 1 with 1.5 hour cut to 1.20 with 20-minute cut;
(H) lip and clearance angles: 1 with lip angle 68 degrees to 1.023 with lip angle of 61 degrees;
(J) elasticity of the work and of the tool: 1 with tool chattering to 1.15, with tool running smoothly.
Taylor's machining time reduction is given the name "Time Study." Time study became a principal technique of Industrial Engineering. But in the evolution of the discipline and profession, overtime, the s focus on study of man's work increased and time study became a subject or method that develops the standard time prescription for the method developed using method study. Method study also focused on manual work only primarily. A subject named "Work Study," a combination of method study and time study or work measurement became popular. Machine work based industrial engineering slow disappeared from industrial engineering. Professor Narayana Rao, brought the focus on machine back in industrial engineering by proposing "machine work study" as an important area in productivity improvement and industrial engineering. Machine based industrial engineering is part of Toyota Production System and was described by Shigeo Shingo in his book. Jidoka, a pillar of TPS, also is interpreted as machines that do not produce waste which indicates machine based productivity improvement. Machine work study involves evaluating each element of machine work with the current possible best practice, improving it appropriately and integrating all the elements to give the highest productivity, lower cost or lowest time. Element level improvement and integrating elements to get the best system improvement has to occur one after another in industrial engineering. Element level thinking and holistic thinking both have to take place in productivity improvement.
To do machine work study, industrial engineers required the basic knowledge and awareness of periodic developments in machine tool and cutting tool engineering and process planning. Productivity science discovers and codifies variables that have an effect on productivity. Industrial engineers have to combine productivity science with knowledge of machine tools and process planning to do productivity engineering.
Taylor's Contribution to Machining Time Reduction and Machining Science/Productivity Science
The first scientific studies of metal cutting were power requirements for various operations so that steam engines of appropriate size could be selected for tools. A number of researchers constructed crude dynamometers and conducted systematic experiments to measure cutting forces. The best known was E. Hartig, whose 1873 book was a standard reference on the subject for many years. Development of more advanced dynamometers occupied researchers after Hartig's book was published. In addition, several studies of the mechanism of chip formation were carried out, most notably by Time, Tresca, and Mallock. By carefully examining chips, these researchers recognized that chip formation was a shearing process.
In 1868 Robert Mushet, an English steel maker, developed an improved tool steel. It was a Tungsten alloy which proved to be self hardening. Mushet took extraordinary measures to prevent the theft of his recipe and the process he used is unknown to this day. The material was superior to carbon steel for cutting tools and was widely used in both Europe and America.
The great historical figure in the field of metal cutting, Frederick W. Taylor, was active at the end of the nineteenth century. Taylor became more famous as the founder of scientific management, and many books on scientific management do not mention his work in metal cutting. The metal cutting work, however, was crucial to the implementation of his productivity engineering and management theories. Books on machining still mention Taylor and his contribution to metal cutting theory.
As foreman of the machine shop, Taylor felt that shop productivity could be greatly increased if a quantitative understanding of the relation between speeds, feeds, tool geometries, and machining performance can be established and the right combination of cutting parameters are specified by managers and used by machinists. Taylor embarked on a series of methodical experiments to gather the data necessary to develop this understanding. The experiments continued over a number of years at Midvale and the nearby Bethlehem Steel Works, where he worked jointly with metallurgist Maunsel White. As a result of these experiments, Taylor was able to increase machine shop productivity at Midvale by hundred percent even though in certain individual jobs and machines, productivity increases was as much as a factor of five. One of Taylor's important practical contributions was his invention of high speed steel, a cutting tool material. The material permitted doubling of cutting speed, which in turn permitted doubling spindle speed for the same diameter of the work and thereby increase in feed which reduced machining time.
Taylor also established that the power required to feed the tool could equal the power required to drive the spindle, especially when worn tools were used. Machine tools of the day were underpowered in the feed direction, and he had to modify all the machines at the Midvale plant to eliminate this flaw. He also demonstrated the value of coolants in metal cutting and fitted his machines with recirculating fluid systems fed from a central pump. Finally, he developed a special slide rule for determining feeds and speeds for various materials.
Taylor summarized his research results in the landmark paper On the Art of Cutting Metals, which was published in the ASME Transactions in 1907. The results were based on 50,000 cutting tests conducted over a period of 26 years. Taylor's also indicated the importance of tool temperatures in tool life and developed the famous tool life equation. His writings clearly indicate that he was most interested in efficiency and economy in his experiments and writings.
Machine tools built after 1900 utilized Taylor's discoveries and inventions. They were designed to run at much higher speeds to take advantage of high speed steel tools. This required the use hardened steel gears, improved bearings and improved bearing lubrication systems. They were fitted with more powerful motors and feed drives and with recirculating coolant systems.
The automotive industry had become the largest market for machine tools by World War I and it has consequently had a great influence on machine tool design. Due to accuracy requirements grinding machines were particularly critical, and a number of specialized machines were developed for specific operations. Engine manufacture also required rapid production of flat surfaces, leading to the development of flat milling and broaching machines in place of shapers and planers. The development of the automobile also greatly improved gear design and manufacture, and machine tools were soon fitted with quick-change gearing systems. The automotive industry also encouraged the development of dedicated or single purpose tools. Early examples included crankshaft grinding machines and large gear cutting machines. It led to the development of transfer machine. An in-line transfer machine typically consists of roughly thirty highly specialized tools (or stations) connected by an automated materials handling system for moving parts between stations. The first was built at Henry Ford's Model T plant in Detroit. . Transfer machines required very large capital investments but the cost per piece was lower than for general purpose machines for the production volumes of hundreds of thousands required in auto industry.
In the 1930's a German company introduced sintered tungsten carbide cutting tools, first in brazed form and later as a detachable insert. This material is superior to high speed steel for general purpose machining and has become the industry standard.
A great deal of research in metal cutting has been conducted since 1900. A bibliography of work published prior to 1943 was compiled by Boston, Shaw and King. The shear plane theory of metal cutting was developed by Ernst and Merchant and provided a physical understanding of cutting processes which was at least qualitatively accurate for many conditions. Trigger and Chao and Loewen and Shaw developed accurate steady-state models for cutting temperatures. A number of researchers studied the dynamic stability of machine tools, which had become an issue as cutting speeds had increased. This resulted in the development of a fairly complete linear theory of machine tool vibrations. Research in all of these areas continues to this day, particularly numerical analysis work made possible by advances in computing. All these discoveries and their implementation in machine tools gives higher productivity in machining.
One of the most important innovations in machine tools was the introduction of numerical control. Today CNC machine tools are the most used ones.
New tool materials were invented. A variety of ceramics are currently used for cutting tools, especially for hardened or difficult-to-machine work materials. Ceramic and diamond tools have replaced carbides in a number of high volume applications, especially in the automotive industry. Carbides (often coated with ceramic layers) have remained the tool of choice for general purpose machining. There has been a proliferation of grades and coatings available for all materials, with each grade containing additives to increase chemical stability in a relatively narrow range of operating conditions. For many work materials cutting speeds are currently limited by spindle and material handling limitations rather than tool material considerations. Dozens of insert shapes with hundreds of integral chip breaking patterns are available now.
Chapter 13. Machining Economics and Optimization
in Metal Cutting Theory and Practice - Stephenson - Agapiou, 2nd Edition
Economic Considerations are important in designing the machining process of a component. Each operation done on a machine involved number of decisions. There is more than one approach for doing an operation and each approach will have as associated machining time, part quality and cost of machining. An effective and efficient methodology is to be employed to attain the specified quality of the operation with the least cost. The machining cost of an operation on a component is made of several components. They include machine cost, tool cost, tool change cost (includes set up), handling cost, coolant cost etc. Some of these costs vary significantly with the cutting speed is different directions. At a certain cutting speed we get the minimum cost and at certain other cutting speed we get the least machining time. There is a need to calculate these minimum point cutting speeds for each work material, tool material and machine tool combinations. F.W. Taylor developed slide rules for this purpose. Now those slide rules are not in place, but machining handbooks and machine tool/cutting tool manufacturers provide guidance. Process planners and industrial engineers need to do the required calculations depending on the trial production within their plans. Time Estimates Required Total Production Time for an Operation, TTO =
Tm + (Tm/Tl)Tlul + Tcs + Te + Tr + Tp + Ta + Td + Tx)
Where
TTO = Total Production Time for an Operation
Tm = Cutting time
Tl = Tool life
Tlul = Tool unloading and time
Tcs = Tool interchange time
Te = Magazine travelling time
Tr = Approach time
Tp = Table index time
Ta = Acceleration time
Td = Deceleration time
Tx = Tool rapid travel time
Time study used for machine work study has to determine these time times from formulas as well as time study observations for the existing way and proposed way to validate the time reduced by the operation analysis based on operation study and time data.
Constraints for Minimizing the Machining Time - Cost
Allowable maximum cutting force, cutting temperature, depth of cut, spindle speed, feed, machine power, vibration and chatter limits, and party quality requirement.
Industrial engineers must have knowledge of maximum permissible depth of cut, feed and cutting speed.
Industrial engineers have to monitor research and continuously update their understanding of limit to the constraints. Developments in engineering and industrial engineering keep increasing the quantity of limits in favor of more productivity.
Holding Cutters and Workpieces on Milling Machines
Cutter Mounting
Workpiece Fixturing
Dividing Heads
Universal Dividing Heads
Modes of Indexing
Basic Information on Milling
Milling machines are employed for machining flat surfaces, contoured surfaces, complex and
irregular areas, slotting, threading, gear cutting, production of helical flutes, twist drills, and spline
shafts to close tolerances.
Peripheral Milling
In peripheral milling, the cutting occurs by the teeth arranged on the periphery of the milling cutter,
and the generated surface is a plane parallel to the cutter axis. Peripheral milling is usually performed on a horizontal milling machine. For this reason, it is sometimes called horizontal milling.
Up-Milling (Conventional Milling)
Up-milling is accomplished by rotating the cutter against the direction of the feed of the WP
Down-Milling (Climb Milling)
Down-milling is accomplished by rotating the cutter in the direction of the work feed,
Advantages of down-milling include the following:
Fixtures are simpler and less costly, as cutting forces are acting downward.
Flat WPs or plates that cannot be firmly held can be machined by down-milling.
Cutter with higher rake angles can be used, which decreases the power requirements.
Tool blunting is less likely.
Down-milling is characterized by fewer tendencies of chattering and vibration, which leads
to improved surface finish.
In face milling, the generated surface is at a right angle to the cutter axis.
Face milling is usually performed on vertical milling machines; for this reason, the process is called vertical milling, which is more productive than plain milling.
Milling Cutters
1. Plain milling cutters are either straight or helical ones. Helical milling cutters are preferred for large cutting widths to provide smooth cutting and improved surface quality. Plain milling cutters are mainly used on horizontal milling machines.
2. Face milling cutters are used for the production of horizontal, vertical , or inclined flat surfaces. They are used on vertical milling machines, planer type milling machines, and vertical milling machines with the spindle swiveled to the required angle ฮฑ, respectively.
3. Side milling cutters are clamped on the arbor of the horizontal milling machine and are
used for machining of the vertical surface of a shoulder or cutting a keyway
4. Interlocking (staggered) side mills mounted on the arbor of the horizontal
milling machines are intended to cut wide keyways and cavities.
5. Slitting saws are used on horizontal milling machines.
6. Angle milling cutters, used on horizontal milling machines, for the production of longitu dinal grooves or for edge chamfering.
7. End mills are tools of a shank type, which can be mounted on vertical milling machines (or
directly in the spindle nose of horizontal milling machines). End mills may be employed in
machining keyways or vertical surfaces.
8. Key-cutters are also of the shank type that can be used on vertical milling machines. They
may be used for single-pass milling or multipass milling operations.
9. Form-milling cutters are mounted on horizontal milling machines. Form cutters may be
either concave or convex.
10. T-slot cutters are used for milling T-slots and are available in different sizes. The T-slot is
machined on a vertical milling machine in two steps:
Slotting with end mill
Cutting with T-slot cutter 11. Compound milling cutters are mainly used to produce compound surfaces. These cutters
realize high productivity and accuracy . 12. Inserted tool milling cutters have a main body that is fabricated from tough and less expensive steel. The teeth are made of alloy tool steel, HSS, carbides, ceramics, or cubic
boron nitride (CBN) and mechanically attached to the body using set screws and in some
cases are brazed. Cutters of this type are confined usually to large-diameter face milling
cutters or horizontal milling cutters. 13. Gear milling cutters are used for the production of spur and helical gears on vertical or
horizontal milling machines. Gear cutters are form-relieved cutters, which are used to mill contoured surfaces. They are sharpened at the tooth face.
Hobbing machines and gear shapers are used to cut gears for mass production and high accuracy demands.
DIVIDING HEADS
Dividing heads are attachments that extend the capabilities of the milling machines. They are mainly employed on knee-type milling machines to enhance their capabilities toward milling straight and helical flutes, slots, grooves, and gashes whose features are equally spaced about the circumference of a blank (and less frequently unequally spaced). Such jobs include milling of spur and helical gears, spline shafts, twist drills, reamers, milling cutters, and others. Therefore, dividing heads are capable of indexing the WP through predetermined angles. In addition to the indexing operation, the dividing head continuously rotates the WP, which is set at the required helix angle during milling of helical slots and helical gears. There are several versions of dividing heads:
Plain dividing heads are mainly used for indexing milling fixtures.
Universal dividing heads.
Optical dividing heads are commonly used for precise indexing, and also for checking the
accuracy of marking graduation lines on dial scales.
Tech Tip: 45° vs 90° Face Milling
Advantages and Disadvantages of Using a 45-degree Face Mill vs. a 90-degree Face Mill
To achieve greater productivity and problem-free milling, use a lead angle cutter whenever possible. Chip thickness is affected by the lead angle. The greater the lead angle, the greater the chip-thinning effect. https://www.kennametal.com/in/en/resources/technical-tips/milling/tech-tip--124---45--vs-90--face-milling.html
News and Information of Machining Elements in Milling
1981
Chapter 14 Production Milling in
Production Processes: The Productivity Handbook
Roger William Bolz
Industrial Press Inc., 1981 - Technology & Engineering - 1089 pages
Reviews all the latest developments and refinements, including their design details, materials, practical tolerances, and working finishes. Allows the reader to objectively evaluate and compare different processes and equipment with their inherent advantages for any particular https://books.google.co.in/books?id=C4SUXiL7gB0C&pg=SA14-PA1#v=onepage&q&f=false
Book preview link: https://books.google.co.in/books?id=C4SUXiL7gB0C
1999
10/15/1999 | 9 MINUTE READ
Tooling Tips For High Productivity Milling
Today's machining centers feature higher spindle speeds and feed rates, but if you want to push this capability to the limit, there are some tooling considerations that must be addressed. https://www.mmsonline.com/articles/tooling-tips-for-high-productivity-milling
Komatsu Tech-innovation
PDF
The crankshaft miller, a leading product of the machine tool business of Komatsu Machinery Corporation, has been model-changed targeting “Improved working environment,” “Energy saving,” “Enhanced flexibility” and “Enhanced productivity.” The new miller was introduced into the market in 2007. The background, technologies and features of the new product are described. https://home.komatsu/en/company/tech-innovation/report/pdf/159-08_E.pdf
Patent: Milling cutter for the milling of exotic materials such as titanium alloys, stainless steel, nimonic alloys etc.
Milling cutter manufacturing method
With Rolls Royce
This invention relates to a method of manufacturing a milling cutter for the milling of so-called exotic materials such as titanium alloys, stainless steel, nimonic alloys etc, which are notoriously difficult to machine.
A method of manufacturing a milling cutter in accordance with the preamble of claim 1 is known from HELLE H.J. "NEUE TECHNIK ZUM SCHLEIFEN VON GESENKFRรSERN", WERKSTATTSTECHNIK, SPRINGER VERLAG, BERLIN, vol. 79, no. 3, 01/03/1989, pages 153-157.
The aerospace industry makes extensive use of titanium alloys etc, and, in common with other industries, continually seek to reduce costs of manufacture through through either outsourcing to cheaper economies or increasing production. https://patents.google.com/patent/EP2121243B1/en
2008
KSCM AluMill face-milling system from Kennametal for high-productivity
With a steel and aluminum body construction that offers reduced weight, improved rigidity and vibration-dampening characteristics, the KSCM AluMill face-milling system from Kennametal is designed to achieve high speeds and high-productivity results, especially for high-volume aluminum milling operations.
January 30, 2008
In particular, automotive applications such as engine blocks and cylinder heads can benefit from the KSCM AluMill system’s design and performance. KSCM AluMill cutters are available between 2.5 in. and 12 in. diameters https://www.canadianmetalworking.com/canadianmetalworking/product/cuttingtools/face-milling-system-offers-improved-rigidity
2010
Performance Improvement of the Mitsubishi Heavy Industries Vertical Precision Milling Machine
MVR Allows High-Accuracy Processing of Automotive Molds and
High-Efficiency Production of Large Molds to be Realized
Mitsubishi Heavy Industries Technical Review Vol. 47 No. 4 (December 2010) https://home.komatsu/en/company/tech-innovation/report/pdf/159-08_E.pdf
The SORALUCE SLP fixed table travelling column machine
The SORALUCE SLP fixed table travelling column machine is a large capacity machine designed in a compact and ergonomic format, offering great flexibility. The machine offers high precision finishing results, based on a unique traditional machine architecture: table attached column
supported by a separate rear guide, to improve machine stability, whilst maintaining its very low centre of gravity. It is the ideal machine for several applications in different sectors such as industrial vehicles, moulds and dies, capital goods and medium sized precision engineering components, ensuring highest precisions and efficiency results. https://www.danobatgroup.com/media/uploads/prensa/soraluce-slp-fixed-table-travelling-column-milling-centre.pdf
Patent for an Improved Shell End Mill
Inventor Berend Denkena, Dennis Nespor
Current Assignee Leibniz Universitaet Hannover
In milling, productivity is a crucial issue. This is especially true for roughing, with a large chip removal rate. Here, to achieve as far as possible in the shortest possible processing time of the final contour by coarse-toothed tools , large depth of cuts are applied, so that a large chip volume is created. Roughing processes are used in particular in the production of integral components of titanium alloys and aluminum alloys for the aerospace industry.
Shell end mills with indexable inserts have the advantage that damaged and / or worn indexable inserts can be replaced individually. The exchangeable indexable inserts can be arranged spirally next to each other on the tool body, so that the adjacent indexable inserts can each jointly form a cutting edge. Shell end mills can achieve high productivity and process reliability, e.g. titanium alloys as well as other difficult-to-machine materials or steel alloys and aluminum alloys.
The present invention relates to a milling tool, in particular a shell end mill, with at least two indexable inserts, wherein the two indexable inserts in the longitudinal direction (y) of the shell end mill are offset from each other in such a way that they overlap one another in an overlapping region by an overlap (t), and wherein the two indexable inserts are offset in the circumferential direction (U) of the shell end mill in such a way that their cutting edges form a resulting cutting edge of the shell end mill. The milling tool is characterized in that at least one cutting edge of at least one indexable insert, preferably both indexable inserts, at least in sections has a contour, so that at least partially a not-just resulting cutting edge. of the milling tool yields. https://patents.google.com/patent/DE102016104005A1/en
Analyzing the Effect of Machining Parameters Setting to the Surface Roughness during End Milling of CFRP-Aluminium Composite Laminates
M. Nurhaniza, M. K. A. M. Ariffin, F. Mustapha, and B. T. H. T. Baharudin
Research Article | Open Access
International Journal of Manufacturing Engineering
Volume 2016 |Article ID 4680380
The machining parameters involved in this experiment are cutting speed, feed rate, and depth of cut. The main objective is to find the combination of machining parameters to achieve low surface roughness during end milling.
The workpiece materials is made by the combination of carbon fiber reinforced polymer (CFRP) and aluminium alloy 2024-T3. In this experiment, the selected cutting tool is polycrystalline diamond (PCD) end mill with 6 mm diameter and 0.2 mm corner radius.
The highest value of surface roughness is found when the feed rate = 1600 mm/min and spindle speed = 3000 rpm. Generally, the combination of high spindle speed and low feed rate produces better surface finish, supported by previous findings of others. https://www.hindawi.com/journals/ijme/2016/4680380/
TVS MOTOR Co. Ltd
September 20, 2016Abhishek D20150 Comments
Title of case study:
Productivity improvement and flow manufacturing in machining fixtures and gauges through innovation and design standardization. https://productivity.imtma.in/tvs-motor-co-ltd/
HOW TO MAXIMIZE MACHINE PRODUCTIVITY: CHIP THINNING
Kip Hanson
Chip thinning is often radial in nature, but can be axial for face milling.
Trochoidal toolpaths allow for lighter radial cuts at higher feed rates and longer axial engagement, thus reducing cutting forces and improving tool life.
Newer, high-performance end mills, harder carbide, chip evacuation and firmer grips—and other tips and tricks, are all part of the new programming paradigm for maximizing machine productivity. https://www.mscdirect.com/betterMRO/metalworking/how-maximize-machine-productivity-chip-thinning
MILLING TECHNIQUES TO IMPROVE METAL REMOVAL RATE
Introduction of inserts made of KCSM40 for Millinh Ti-6Al-4V
Users of inserts made of KCSM40 are now machining Ti-6Al-4V at 160 surface feet per minute when they might have reached only 140 SFM in the past.
A 4-inch diameter cutter could have 8, 12 or 15 teeth. A 15-tooth cutter of that size considered very high density. If you use a 15-tooth cutter, you’re improving your productivity because you’ll have more teeth in the cut. But you have to make sure that spindle can take the load by doing cutting-force calculations and use the appropriate highest-density cutter.
Owners of rigid machines equipped with a low-speed spindle can use a “helical” cutter such as Kennametal’s new Harvi Ultra 8X, which is designed to offer longer tool life than traditional cutters at high MMR
Designed to mill grooves up to 6 millimeters wide, the CoroMill QD cutter from Sandvik Coromant, of Fair Lawn, New Jersey, uses geometry and a novel coolant delivery system to solve chip-related problems. The QD’s insert geometry produces chips that are thinner than the groove being machined. These chips are flushed out by coolant delivered through the cutter body to each cutting edge. Besides boosting MRR, this system dramatically increases tool life and the surface quality of milled components. https://www.mscdirect.com/betterMRO/metalworking/milling-techniques-improve-metal-removal-rate
Pocket NC V2 Mill Improvements
Summer 2018 Update by Pocket NC August 17, 2018
We chose to switch to using a THK Cross-Roller Ring bearing. This bearing offers the ability to carry a load in all directions: axial, radial and moment loads are supported. The V2 now achieves a higher level of rigidity in the rotary axes of the machine without increasing the exterior dimensions of the Pocket NC. The rigidity of the of the rotary axes was improved by a factor of 2 and the run out of the rotary axes was decreased by a factor of 4, the strength/force of the rotary axes movement is about double what is was before due to less friction in the bearing. All this adds up to a more rigid machine which results in improved machining performance in material removal rate and surface finish.
We discovered that our calibration of the rotary axes on the machine was a weak link in our system. Our system relied on checking only two points, the home position and one other point in the rotation.
We developed some new fixtures that allowed us to check 8 points rather than 2. This revealed that there could be errors of up to 0.5° at points in between the two points that we previously checked.
We ultimately determined that it was due to some inconsistencies in the manufacturing of the gears that we build in-house. We made some changes to our manufacturing process and were able to correct about 50% of the error, down to a max error of about 0.25°. We continued with our manual measurements at 8 points and added rotary axis compensation at 4 points in the travel of both A and B. This resulted in another decreased rotary position error of about 50% down to about 0.12°. Enter the Renishaw probe. Our software and hardware team have been working closely together on developing a solution that delivers consistent, accurate results. We are now able to compensate the rotation of the A and B axes with enough precision to reach rotational accuracy of 0.05° at every angle.
Effects of Machining - Milling Parameters on the Quality in Machining of Aluminium Alloys Thin Plates
Published: 24 August 2019, Metals https://www.mdpi.com/2075-4701/9/9/927/pdf
Productivity Increase – Model-based optimisation of NC-controlled milling processes to reduce machining time and improve process quality
C.Brecher⁎ M.Wiesch⁎ F.Wellmann⁎
IFAC-Papers OnLine
Volume 52, Issue 13, 2019, Pages 1803-1807 https://www.sciencedirect.com/science/article/pii/S2405896319314442
Multi-Response Optimization of Face Milling Performance Considering Tool Path Strategies in Machining of Al-2024
Ali, Raneen Abd et al. “Multi-Response Optimization of Face Milling Performance Considering Tool Path Strategies in Machining of Al-2024.” Materials (Basel, Switzerland) vol. 12,7 1013. 27 Mar. 2019, doi:10.3390/ma12071013 https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6479395/
Multi Objective Optimization in CNC End Milling of Inconel 718 Super Alloy by Taguchi-Grey-Fuzzy Method
2019 International Conference on Nascent Technologies in Engineering (ICNTE) https://ieeexplore.ieee.org/document/8945898
Integrated optimization of cutting tool and cutting parameters in face milling for minimizing energy footprint and production time
Xingzheng Chen, Congbo Li, Ying Tang, Li Li, Yanbin Du, Lingling Li
Energy
Volume 175, 15 May 2019, Pages 1021-1037 https://www.sciencedirect.com/science/article/abs/pii/S0360544219303561
Optimisation of Cutting Tool and Cutting Parameters in Face Milling of Custom 450 through the Taguchi Method
Research Article | Open Access
Advances in Materials Sciene and Engineering
Volume 2019 |Article ID 5868132 | 10 pages https://www.hindawi.com/journals/amse/2019/5868132/
Boosting Shop Productivity by Applying High Efficiency Milling Techniques
22 Dec 2019
Autodesk Fusion 360
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Precise Measurements in a turning-milling Machining Centre
03/28/2019 - Measuring Components
Production Metrology from BLUM at Tries
Most of the milling machines at Tries are equipped with LaserControl measuring systems from BLUM. Laser measuring systems are indispensable in production, and the tool is measured after each machining operation to detect any tool breakage. The portfolio of various touch probes and laser measuring systems is further enhanced with two Z-Nano tool setting probes that are used on a Matec machining centre with two tables. This allows machining on one table and the clamping and unclamping of workpieces on the other. The Z-Nano also permits very high probing speeds in order to keep measuring times as short as possible. https://www.blum-novotest.com/en/news/news-stories/detail/news/precise-measurements-in-a-turning-milling-machining-centre.html
Productive aluminium milling for automotive powertrains
2019-03-28
Sandvik Coromant offers a well-rounded selection of milling cutters for aluminium automotive components. M5Q90 is the cubing specialist of the M5 family of milling concepts, in other words it is designed for the first roughing stage to clean the surfaces of newly cast parts. These shoulder cutter with indexable inserts have cutting edges only on the radial periphery of the tool body. M5R90 is a roughing and semi-finishing concept for shoulder milling operations, with cutter diameters ranging between 63 and 250 mm (2.48–84 inch). The tool has re-grindable PCD tips brazed to a steel cartridge, which allows axial adjustments and consequently large depths of cut, up to 8 mm (0.315 inch). Two radius options, 0.4 mm and 0.8 mm (0.016 / 0.031 inch), are available, depending on the cartridge model. M5R90 is a reliable, easy-to-use cutter that can be optimally teamed up with M5B90 when excellent surface finishes are required (below 4Rz). https://www.sandvik.coromant.com/en-gb/mww/pages/t_crankshaft.aspx
Face milling cutter combines productivity with cost-effectiveness
11 JUNE 2019
Walter GB says the new M2127 PCD face milling cutter is a logical continuation of the company’s M4000 system concept.
Users can reduce costs by utilising a universal system of inserts for different tools and differing applications for aluminium machining.
Designed for high-speed applications, the cutter is available in diameters up to 250mm and is ideal for both roughing and finishing aluminium as well as for smear milling and for finishing bi-metal components. https://www.aero-mag.com/walter-gb-m2127-pcd-face-milling-cutter/
July 2019
The first fully automatic milling machine for aluminium ingots
Highly automated system cuts machining-cycle times by more than 30 percent.
Kreuztal, Germany, 29 July 2019 GEORG will be unveiling its new ultramill series of portal-type milling machines for milling of aluminium ingots at the 2019 Aluminum USA. It machines all surfaces, including the end and side faces, in just two clamping cycles. A high level of automation and a high machining speed achieve a significant increase in system throughput compared to machines customary up to now. https://www.georg.com/en/press/press-release/news/the-first-fully-automatic-milling-machine-for-aluminium-ingots-1/
November 2019
KOR 5 from Kennametal for Productivity in aluminum roughing for aerospace
Kennametal announced its latest innovation in high-velocity aluminum roughing, the KOR 5 solid carbide end mill. Designed for maximum productivity in aerospace machining, with this five-flute end mill table feed rates increase up to 66 percent compared to commonly used three-flute tools—redefining productivity for aircraft manufacturers and their suppliers. https://blog.wor-con.com/new-kor-5-solid-carbide-end-mills-offer-maximum-productivity/?lang=en
December 2019 Tungaloy’s DoForce-Tri 07 insert maximizes shoulder milling productivity
DoForce-Tri 07 - High productive and cost-effective shoulder milling cutter with 07 size insert
1 Jul 2019
TungaloyCorporation
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Tungaloy’s New TungEight-Mill Light Cutting Face Mill Increases Productivity in Low HP Machines
16. Dec. 2019.
Iwaki, December 2019 — Tungaloy unveils TungEight-Mill face milling cutter for extremely light cutting with low power consumption.
TungEight-Mill incorporates single-sided positive inserts with economical 8 cutting edges for heavy roughing to mirror finishing of various material faces. The cutter is designed to provide light cutting action suitable for weak fixtures and low horsepower machines with a BT-30 connection. A high positive rake angle of the insert and its optimal orientation on the cutter contributes to forming a helical shaped chip, allowing smooth chip evacuation and application security. The feature is particularly effective when machining low carbon steel and stainless steel with chip breaking difficulty and tendency to smear. https://www.tungaloy.com/press-release/new_tungeight-mill/
JWD Machine Inc. of Fife, Wash.
The company has been recognized as a Boeing Supplier of the Year award winner, and it is known by others outside of the aerospace manufacturing industry for its development of the widely used Techni-Grip™ fixturing system. With its long and growing list of accomplishments, JWD understands that it has a reputation to uphold in the face of relentless competition, which is why the company embraces and leads with high-performance machining technology. https://www.radical-departures.net/articles/titanium-milling-automation-productivity-soar-at-jwd/
Thread milling achieves high productivity in certain applications.
March 2020
Thread milling should always be the application of choice when:
Machining asymmetric/non-rotating components
Machining materials that cause chip breaking and chip evacuation problems
Machining tough materials that create high cutting forces
Machining against a shoulder or close to the bottom of a blind hole
Machining thin-walled components
Component set-ups are unstable
Tool inventory needs to be minimized
You do not want to risk tap breakage on expensive parts – thread mills can always be removed from the component completely
A machine tool capable of simultaneous movement in the X, Y and Z-axis directions is required
Physics-Guided Machine Learning for Increased Milling Productivity
SMART MANUFACTURING/INDUSTRY 4.0
March 18, 2020 2:35 pm - 3:00 pm
This presentation will describe the application of artificial intelligence (AI) to precision part machining. Specifically, it will summarize current efforts toward autonomous operation, or the ability of a machine to understand its current state and respond accordingly. The innovation is the combination of machine learning and physics-based models to provide hybrid physics-guided machine learning (PGML) approaches that improve the accuracy, physical consistency, traceability, and generalizability of model predictions. This disruptive capability is poised to redefine manufacturing from the machine tool to the enterprise across the global economy. The research efforts leverage current activities in AI, machining process modeling, and in-process sensing. The approach is to use experimental capabilities to generate data, define physics-based process models, couple the data and physics-based models with machine learning algorithms in new hybrid modeling approaches, and test the subsequent operating parameter predictions.
Learning Objectives:
Understand machine learning algorithms available for manufacturing modeling
Understand machining process models that can be used for performance prediction
Understand how physics-based and machine learning models can be combined to improve milling productivity
COMPACT MILLING MACHINE ENDURA® 700LINEAR
The ENDURA® 700LINEAR is a state-of-the-art 5-axis milling machine in compact portal construction with linear motor drive technology and 5 CNC-controlled simultaneous axes. This machine tool is especially suited for the rational finish-machining from 5 sides of work pieces made of plastics, composite materials (carbon fibre reinforced plastic, glass fibre reinforced plastic), model making block material (ureol) and aluminium, as well as HSC-machining of cast iron and steel materials.
The compact 5-axis milling machine ENDURA® 700LINEAR features a high structural rigidity, is extremely dynamic and reaches tight accuracies. These characteristics result in an optimal motion control and the maximum possible productivity. Despite its compact contruction and small installation surface, the 5-axis milling machine offers a large machining space. Futhermore, this machine tool does not require a foundation. With an acceleration of up to 3.5 m/sec², the FOOKE ENDURA® 700LINEAR is one of the latest high speed milling machines.
Optimized roughing, also called high-efficiency milling -Rough Faster With Better Tool Life in Difficult Materials
Optimized roughing, also called high-efficiency milling, is an effective way to improve material removal rates and tool life for titanium and hard-to-machine alloys, but knowing when to use it is as important as knowing how.
Milling dynamic model based on rotatory Euler–Bernoulli beam model under distributed load
Qi Yao, Ming Luo, Dinghua Zhang
Applied Mathematical Modelling
Volume 83, July 2020, Pages 266-283
Highlights
•Cutter-holder-spindle dynamic system is simplified considering milling conditions.
•A rotatory Euler–Bernoulli beam model is used on cutter vibration modeling.
•Cutting force fluctuation is involved with cutter vibration synthesized. https://www.sciencedirect.com/science/article/abs/pii/S0307904X20301001
Quality Retention Knobs for Toolholders
Ohio-based T.J. Davies, a manufacturer of high-quality retention knobs utilizes certified 86L20 and 9310 steel drawn in the United States providing retention knobs with high reliability at higher RPMs during CNC machining.
86L20, a low alloy nickel, chromium, molybdenum case hardening steel, has high hardenability without temper brittleness, along with good external and internal strength, and high wear-resistance. 9310, a low alloy steel composed mostly of nickel and chromiumis still higher quality steel. This alloy also has high hardenability, core hardness and fatigue strength, which makes it an excellent steel for use in heavy-duty machinery.
Theos 98 SL is equipped with a table, with double pinion and backlash elimination system, which allows 5 axis machining tasks. Added to its high feed rates (up to 40 m/min), this results in an outstanding productivity.
Online adaption of milling parameters for a stable and productive process
Benjamin Bergmann, Svenja Reimer.
CIRP Annals
Volume 70, Issue 1, 2021, Pages 341-344
In fully autonomous machine tools, it is essential to independently select suitable process parameters and adapt them on-the-fly to the appropriate process conditions in a self-controlled manner. This paper introduces a new approach enabling machines during the milling process to learn which parameters lead to a stable process with maximum productivity and to adjust them autonomously. This approach enables the machine tool to independently find stable process parameters with maximum productivity.
Walter presents the Xtra tec® XT M5009 and M5012 Face Milling Cutters for Increased Productivity.
The M5009 and 5012 face milling cutters are of 12 mm insert size. With an approach angle of 45° and thanks to its higher number of teeth, the M5009 (diameter 25–160 mm) is ideal for increasing productivity in mass production. The M5012 (diameter 32–160 mm) has a steep approach angle of 88°, making it possible to work with larger machining conditions and depths of cut (8 or 10 mm) and is less affected by interference contours. Both face milling cutter families are designed for high feed rates per tooth at maximum process reliability. The tools with a medium or large pitch for insert size 12 are designed with carbide shims. These increase the tool life and protect the milling body against damage in the event of an insert fracture. Inclined clamping screws make access easier and shorten the time required to replace inserts.
Milling Parameter Selection to Lower Specific Cutting Energy During Machining of Alloy Steels
Posted: 5 Mar 2020
The current study focuses on the selection of optimum milling parameters set in Vertical Milling Machine for machining Stainless Steel and Bright Steel, considering Surface Finish and Specific Cutting Energy as output parameters during the process. The cutting speed, feed, depth of cut, cutter diameter and work material are considered as potential input parameters affecting the output parameters of the milling process. https://papers.ssrn.com/sol3/papers.cfm?abstract_id=3548412
3/28/2019
High Feed Milling Can Reduce Cycle Times 50 Percent
Sponsored Content
This milling strategy reduces cycle time and tool wear by maintaining high feed rates during aggressive machining passes, even in tough materials like tool steels, titanium and Inconel. https://www.mmsonline.com/articles/high-feed-milling-can-reduce-cycle-times-50-percent
Coatings 2020, 10(3), 235; https://doi.org/10.3390/coatings10030235
Published: 4 March 2020
Recent Advances on Coated Milling Tool Technology—A Comprehensive Review
by Vitor F. C. Sousa andFrancisco J. G. Silva https://www.mdpi.com/2079-6412/10/3/235/htm
Milling Fixtures
Links to be added
Design and Development of Milling Fixture -
IJREAMwww.ijream.org › papers
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Design of Milling Fixture in Mass Production of Pivot Block
www.trp.org.in › ARME-Vol.6-No.1-January-June-2017-pp.13-17.pdf
PDF
Keywords: Milling fixture, mass production, CATIA, fixture plate, 3-2-1 principle. I. ..
Development and Design of Fixture for Face Milling ... -
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Fixture should be designed by considering productivity, time, ease of loading and unloading, accuracy etc. So, the aim is to develop and design the fixture for face milling operation on tool shank which interns increases accuracy of angle, ease of loading and unloading and increases productivity.
A Detailed Review on Design and Development of Fixture for ...
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Design and Analysis of Milling Fixture for HMC - Krishi Sanskriti
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Intelligent Fixtures for Active Chatter Control in Milling
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Maximum performance and productivity with the large milling machine W 250 XF
World premiรจre of the most powerful cold milling machine at Bauma
With the new W 250 XF, Wirtgen presents a machine that impresses with high milling performance and simultaneously low specific emissions. It is now available in the USA, Australia, Europe, Japan and Taiwan.
Its dual-engine drive system is controlled by MILL ASSIST to ensure maximum performance.
