|Eko Arif Syaefudin||Department of Mechanical Engineering, Faculty of Engineering, Universitas Indonesia, Kampus UI Depok, Depok 16424, Indonesia|
|Gandjar Kiswanto||Department of Mechanical Engineering, Faculty of Engineering, Universitas Indonesia, Kampus UI Depok, Depok 16424, Indonesia|
|Ario Sunar Baskoro||Department of Mechanical Engineering, Faculty of Engineering, Universitas Indonesia, Kampus UI Depok, Depok 16424, Indonesia|
peripheral milling strategy of using a cylinder cutter is an effective strategy
commonly used on planar or ruled surfaces because of its
5-axis peripheral milling; Faceted models; Tool orientation
The 5-axis machining method is very useful in various aspects of manufactured products, including industrial equipment components, automotive components, and aircraft industrial components. These products require high levels of precision. Even special operational strategies on CNC or another 5-axis machining can provide energy savings (Peng and Xu, 2014). The process of using a peripheral milling strategy is more effective than end milling for planar surfaces. However, it will encounter many obstacles on the sculptured surface. Many manufactured products contain sculptured surfaces with high curvature, which are generally produced using an end milling machining process. The end milling process requires a longer tool path than the peripherals for general surface milling processes. This process applies to both the initial machining process and the final machining process.
Consequently, the total duration of the machining process is also long. One solution to increase efficiency is to replace the end milling method with peripheral milling. This method is advantageous in terms of material removal rate and can reach areas that end milling cannot access, for example, turbine blades (Senatore et al., 2012). On the other hand, the complexity and cost of machining are important variables that affect the final cost of the product (Budiono et al., 2014), and capability in production or operations significantly influences all aspects of the manufacturing strategy (Nurcahyo et al., 2019). The complexity and the machining strategy greatly impact the production cost and manufacturing strategy, so the effectiveness of the capacity of a 5-axis milling strategy needs to be improved.
In general, peripheral milling machining methods have been developed
in various 5-axis milling studies. Most of the solutions are performed using
the analytical method with the ruled surface approach, and mostly for
completing peripheral milling on the local area of ??the entire surface, or to
analyze a limited area, and rarely apply to the entire surface. Research
developed by Gong et al. (2005)
Although the tool periphery's use provides a maximum removal rate, avoiding gouging requires a special strategy. In this study, a peripheral milling method was developed on sculptured surfaces based on the faceted models. This is because the faceted model has many advantages compared to the parametric model, including: (1) it is simpler to represent the model; (2) it is easier to detect and avoid gouging/interference; (3) the topology of the milling process can be adjusted for complex surfaces; and (4) collision checking between tool and surface can be done easily (Kiswanto et al., 2006). The development of the peripheral milling method in this study begins with determining the tool trajectory's cc-point and direction (Syaefudin et al., 2017). According to Kiswanto et al. (2006), each cc-point in the faceted plane will always have normal vector information so that it can be used to determine the feed direction and the initial tool orientation. If the tool's initial orientation at a cc-point causes interference, then a special strategy is required that will be described in this paper. To increase the machining process's effectiveness, sculptured surfaces that can be worked with peripheral milling are divided into groups of machinable areas, while sculptured surfaces that cannot be worked are grouped into non-machinable areas.
This paper has presented the development of a peripheral milling strategy to cover all sculptured surfaces. This method starts from tool orientation, then gouging detection, then a strategy to reverse the orientation tool as an alternative to maximizing peripheral milling oriented tools and finally detecting non-machinable peripheral areas. The machining strategies developed in this research were tested on 3 simulated models using the same machining parameters and were displayed in a 3D simulation. The maximum peripheral milling area that can be worked out of the total surface is indicated by the percentage.
The results of this simulation show that the algorithm is successful and operating well as the first step in developing the peripheral milling strategy for sculptured surfaces. The identification of the non-machinable area can determine the total peripheral milling area.
Based on this study’s
results, further research in this area could potentially develop a strategy as
a solution to milling the area of non-machinable peripheral, for example is by
an end milling strategy.
This research was
developed in the Manufacture Laboratory of the Mechanical Engineering Department
of Indonesia University and was funded by the 2016 PITTA Research Grant.
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