Peter Ižol

Influence of the CAM Parameters and Selection of End-Mill Cutter when Assessing the Resultant Surface Quality in 3D Milling

The paper deals with the effects of CAM data needed to produce desired quality of shaped surfaces in forming dies making. In general, the input CAM data have strong influence to the final surface quality. The shaped surfaces 3D milling has been modeled as end ball milling of the surfaces with defined inclination. The end ball milling is the most common way to finish shaped surfaces. Directions of the milling tools motion and applied cutting conditions have been used to simulate data when setting milling strategies. The resultant machined surface quality has been identified in terms of the surface roughness. The paper introduces recommendations applicable to the programming of the different types of milling strategy when producing form surfaces.

Sampling Based Assessment of the Free-Form Milling Strategies

In this paper, author introduce common needs of increasing surface quality in tool making, a sort of products manufactured by free form milling technology. Principles of the free-form surface decomposition into measurable samples are presented and that is a method of combining CAD modeling with design of sampling objects. Sampling objects are classed both according to their measurability and applied milling strategy. Authors verify experimentally their sampling approach for three milling strategies applied in surface finishing operations while free-form surfaces are investigated in terms of their signed radii. Verification of proposed approach is based on statistical distribution of the measured surface roughness data.

Milling strategies evaluation when simulating the forming dies’ functional surfaces production

Abstract The paper deals with selection and evaluation of milling strategies, available in CAM systems and applicable when complicated shape parts are produced, such as forming dies. A method to obtain samples is proposed and this stems from real forming die surface machined by proper strategies. The strategy applicability for the whole part – forming die – is reviewed by the particular specimen evaluation. The presented methodology has been verified by machining model die and comparing it to the production procedure proposed in other CAM systems.

Influence of Cutting Parameters and Tool Geometry on Thrust Force Behavior in Drilling Ti6Al4V

Titanium alloy Ti6Al4V represents one of the most frequently used alloys in medical as well as in aerospace industry and is considered as a difficult to cut material. In this paper, cutting experiments within throughput drilling were carried out under the varying cutting speed, feed and tool geometry (cutting edge radius and clearance angle). The effects of cutting speed feed and tool geometry on thrust force in drilling Ti6Al4V alloy were investigated applying design of experiment (DoE) according to Taguchi plan L16. The effect of above mentioned parameters was investigated through analysis of the S/N ratios (smaller is better) and ANOVA analysis. All analyses were performed using statistical software Minitab and Matlab. In the case of thrust force, the feed is the main influencing factor, followed by cutting speed, cutting edge radius and clearance angle.

Comparison of Milling Strategies when Machining Freeform Surfaces

The article deals with comparison and evaluation of the milling strategies that are available in CAM systems and are used to produce components with freeform surfaces. For the purpose of the experiment, sample with freeform features was designed to employ different milling strategies when 3 axis machining. Evaluation of the milling strategies was carried out by surface roughness measurement, comparison of the actual machining time with a simulation time as well as visual control of the sample surface with a surface obtained in simulation. Acquired research results can be utilized within production process of tools with sculptured surfaces, such as tools for metal sheet forming, dies, molds for plastics and many others.

The Evaluation of Surface Quality for Particular Parts of Forging Die

Forming dies are often costly for producers and the cost amount is influenced by production process too. If the die is manufactured by machining, proper strategies would necessary to consider as well. The right selection of adequate strategy helps production times shortening, tool wear reducing and those affect production effectiveness. Used strategies and its parameters are often compromise between acceptable surface quality and variations in shape aside, and production time on the other side. The paper presents the way of evaluation of milling strategy based on selected elements of forming die. This allows choosing the adequate strategy for particular shapes of die and also to evaluate them by the reached surface quality. Presented approach is verified by machining forging die cavity for production of connecting rod.

Comparison of Experimental Stamping Punch Machinability Made out of Unconventional Materials

The paper describes experimental stamping punch production from the view machinability and quality of stamping punch active surfaces. The tin car-body stamping punch has been chosen as a subject of experimental work. Two unconventional materials such as Textit J and Fibroflex 5 have been chosen for stamping punch. Milling strategies have been proposed, optimized and verified using CAM software SolidCAM considering the maximum Scallop Height. The final surface quality on selected areas of stamping punch shaped surface has been evaluated by surface roughness parameters Ra and Rz. These have been compared to Scallop Height set in CAM software. Manufactured areas on shaped surface were optically evaluated as well.

Verification of Shaped Surface Manufacturability and Surface Quality of Stamping Die’s Punch

The contribution describes complex solution of stamping punch production from the view manufacturability and quality of stamping punch active surfaces. The application of proposed procedure is shown as an example of manufacturability experimental and production stamping punch designed for complex parts production. There is also proposal of both, the production process and strategies for stamping punch manufacturing. The quality of manufactured parts was reviewed according to its manufactured surfaces by optical evaluation and the roughness measurement on selected areas as well.

Verification of Tin Car Body Production by Unconventional Stamping Method

The contribution deals with verification of tin car body production using single action experimental stamping die. Two methods of car body production were verified - the first one used open die made of tool steel and the second one used closed die made of tool steel with Fibroflex at the bottom of the die. The tin steel sheet TS 245 with thickness 0.28 mm had been used for the car body production. The shapes of pressings were evaluated using the photogrammetric 3D measuring system ARGUS. The ARGUS optical system allowed evaluating the wall thickness change and the deformation on the surface of pressings as well. These values had been compared for both method of the tin car body production.

The Micro-Geometry Evaluation on Steel Sheets after Chemical Surface Treatment

Abstract The protection of metal materials by coatings is one of the most important way to protect the surface against corrosion. Galvanisation of metal surfaces by an electric current is one of the most frequent way of surface treatment due to its wide application. The paper is oriented to the evaluation of the surface quality in terms of micro-geometry. The basic surface of the steel sheet S235JRG2 has been evaluted and compared to the degreased one, galvanized one and surface after galvanizing, chromatizing and phosphating. The microgeometry parameters such as the arithmetical mean deviation Ra, the maximum height of profile Rz, the total height of profile Rt as well as the the mean width of the profile elements RSm and the number of peaks per unit length RPc has been compared.