Simulation of the process of milling and grinding cylindrical surfaces by an oriented tool in one setup

User Rating:  / 0
PoorBest 

Authors:


V.V.Kalchenko, orcid.org/0000-0002-9072-2976, Chernihiv Polytechnic National University, Chernihiv, Ukraine, e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

V.I.Kalchenko, orcid.org/0000-0002-9850-7875, Chernihiv Polytechnic National University, Chernihiv, Ukraine, e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

S.D.Tsybulya, orcid.org/0000-0002-7843-6061, Chernihiv Polytechnic National University, Chernihiv, Ukraine, e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

A.V.Kolohoida, orcid.org/0000-0002-1742-2686, Chernihiv Polytechnic National University, Chernihiv, Ukraine, e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

Ye.Yu.Sakhno, orcid.org/0000-0002-9789-7242, Chernihiv State Institute of Economics and Management, Chernihiv, Ukraine, e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.


повний текст / full article



Naukovyi Visnyk Natsionalnoho Hirnychoho Universytetu. 2022, (4): 066 - 070

https://doi.org/10.33271/nvngu/2022-4/066



Abstract:



Purpose.
Improvement of schemes for processing the cylindrical surfaces of the shafts of gearboxes and transmissions of large-sized equipment. Development of modular spatial models of the processes of milling and grinding of the cylindrical surfaces of the shafts of gearboxes and transmissions of military and civil vehicles. Development of a model for dressing a grinding wheel with a diamond tool.


Methodology.
Creation of general and particular modular mathematical models of the processes of removal of allowance and shaping during rough and finish milling and finishing grinding of non-rigid cylindrical surfaces was carried out using a matrix apparatus for transforming coordinate systems. This made it possible to describe the treatment process using standard matrices. The calculations were carried out in the mathematical package Mathcad. To obtain a graphic display of the mathematical model of the instrumental and machined surfaces, the standard functions of the software package and the developed logical blocks were used.


Findings.
A technique for processing cylindrical surfaces of revolution with an oriented tool is proposed. Roughing, finishing and polishing are carried out in one setup. Roughing and finishing are carried out with an oriented cutter with replaceable multifaceted carbide inserts. The angle of orientation of the cutter is selected from the condition of maximum loading of the end section. Thus, the roughing stock is removed by the end face and by the finishing periphery, while the maximum component of the cutting force is directed along the axis of the part and does not cause deformations in the radial direction. Final finishing is carried out with a wide grinding wheel. The angle of orientation of the grinding wheel is selected from the condition of uniform distribution of the allowance along the periphery. A scheme for dressing the working surface of a grinding wheel with a diamond pencil with a constant feed is proposed.


Originality.
Modular spatial models of the processes of milling and grinding of the cylindrical surfaces of the shafts of gearboxes and transmissions of military and civil vehicles were developed. A model for dressing a grinding wheel is proposed. The use of the proposed models makes it possible to conduct a more detailed analysis of the processes of stock removal and shaping.


Practical value.
Dependencies are proposed for choosing the optimal angles of orientation of the cutter for roughing and finishing milling and the grinding wheel for finishing. The accuracy of parts is increased due to the elimination of the resetting error. The cost of manufacturing is reduced due to the maximum full use of cutting carbide inserts, by turning them and operating the worn finishing edge in the rough milling mode, as well as by increasing the resource of the grinding wheel.



Keywords:
cylindrical surface, three-dimensional modelling, milling, grinding, indexable inserts, space cutting wedge

References.


1. Fedorovich, V., Pyzhov, I., Ryazanova-Khitrovskaya, N., & Voropai, V. (2018). Dynamic mathematical modeling of the diamond burnishing process. Modern technologies of engineering, 13, 142-152.

2. Fedorovich, V., & Pyzhov, I. (2017). 3D modeling of the stress-strain state of the diamond grinding process. Cutting & tools in technological systems, 87, 172-180.

3. Fedorovich, V., Pledge, V., Pyzhov, I., Krivoruchko, D., & Fedorenko, D. (2016). Methodology of 3D modeling of processing of difficult materials. Modern technologies in mechanical engineering, 11, 208-232.

4. Brechera, C., Wellmanna, F., & Epplea, A. (2017). Quality-predictive CAM simulation for NC milling. Procedia Manufacturing, 11, 1519-1527.

5. Denkena, B., Grove, T., & Suntharakumaran, V. (2020). New profiling approach with geometrically defined cutting edges for sintered metal bonded CBN grinding layers. Journal of Materials Processing Technology, 278, 64-73.

6. Jamshidi, H., & Budak, E. (2020). An analytical grinding force model based on individual grit interaction. Journal of Materials Processing Technology, 283, 116700.

7. Kilic, Z., & Altintas, Y. (2016). Generalized mechanics and dynamics of metal cutting operations for unified simulations. International Journal of Machine Tools and Manufacture, 104, 1-13.

8. Kalchenko, Vitalii, Kolohoida, A., Kuzhelny, J., & Morochko, V. (2018). One-pass finishing grinding with crossed axes of a wheel and a cylindrical part. Technical sciences and technologies, 4(14), 9-17.

9. Kalchenko,Vitalii, Kalchenko,Volodymyr, Sira, N., Kalchenko,O., Vynnyk, V., Kalchenko, D., & Morochko, V. (2020). Development of the single-setup milling process model of the shaft support necks and cams. Eastern-European Journal of Enterprise Technologies, 1(106), 48-54. https://doi.org/10.15587/1729-4061.2020.208579.

10. Kalchenko,Vitalii, Kalchenko,Volodymyr, KalchenkoO., Sira,N., Kalchenko,D., Morochko,V., & Vynnyk,V. (2020). Development of a model of tool surface dressing when grinding with crossed wheel and cylindrical part axes. Eastern-European Journal of Enterprise Technologies, (3), 23-29. https://doi.org/10.15587/1729-4061.2020.202441.

11. Ermolaev, V. (2017). Modern grinding machines: new methods of abrasive processing. RHYTHM of machine building, 10, 28-33.

12. Altintas, Y. (2016). Virtual High Performance Machining. In: Procedia CIRP, 46, 372-378.

13. AKKO (2021). Cutting and Connection Systems. Catalogue. Retrieved from https://www.akko.com.tr/download_dosya/akko-cutting-tools-2021-products-catalogue.pdf .

14. ISCAR (2019). Complete Machining Solution. Rotating tool lines. Milling. Hole Making. Tooling Sysytems. Catalogue. Retrieved from https://www.iscar.com/Catalogs/publication-2019/rotating-tools-2019-milling-tools_ua.pdf .

15. ISCAR (2019). Complete Machining Solution. Milling inserts. Catalogue. Retrieved from https://www.iscar.com/Catalogs/publication-2019/rotating-tools-2019-milling-inserts_ua.pdf.

 

Visitors

6238818
Today
This Month
All days
3272
65495
6238818

Guest Book

If you have questions, comments or suggestions, you can write them in our "Guest Book"

Registration data

ISSN (print) 2071-2227,
ISSN (online) 2223-2362.
Journal was registered by Ministry of Justice of Ukraine.
Registration number КВ No.17742-6592PR dated April 27, 2011.

Contacts

D.Yavornytskyi ave.,19, pavilion 3, room 24-а, Dnipro, 49005
Tel.: +38 (056) 746 32 79.
e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.
You are here: Home Archive by issue 2022 Content №4 2022 Simulation of the process of milling and grinding cylindrical surfaces by an oriented tool in one setup