Effect of cutting conditions and tool geometry on process damping in machining

Process damping can be a significant source of enhanced stability in metal cutting operations especially at low cutting speeds. However, it is usually ignored in stability analysis since models and methods on prediction and identification of process damping are very limited. In this study, the effects of cutting conditions and tool geometry on process stability in turning and milling are investigated. The previously developed models by the authors are used in simulations to demonstrate conditions for increased process damping, and thus chatter stability. Some representative cases are presented and verified by experimental data and conclusions are derived

Optimization of 5-axis milling processes using process models

Productivity and part quality are extremely important for all machining operations, but particularly for 5-axis milling where the machine tool cost is relatively higher, and most parts have complex geometries and high quality requirements with tight tolerances. 5- axis milling, presents additional challenges in modeling due to more complex tool and workpiece interface geometry, and process mechanics. In this paper, modeling and optimization of 5-axis processes with cutting strategy selection are presented. The developed process models are used for cutting force predictions using a part-tool interface identification method which is also presented. Based on the model predictions and simulations, best cutting conditions are identified. Also, for finish process of a complex surface, machining time is estimated using three machining strategy alternatives. Results are demonstrated by example applications, and verified by experiments

Optimization of 5-Axis milling processes based on the process models with application to airfoil machining

5-axis milling is widely used in machining of complex surfaces such as airfoils. Improper selection of machining parameters may cause low productivity and undesired results during machining. There are several constraints such as available power and torque, chatter stability, tool breakage etc. In order to respect such constraints proper machining parameters should be determined. In this paper, methodologies for improving 5-axis milling processes are presented. Selection of machining parameters is performed using process simulations. The developed methodologies are presented on an example airfoil

First-principles study of Ti-doped sodium alanate surfaces

We have performed first-principles calculations of thick slabs of Ti-doped sodium alanate (NaAlH_4), which allows to study the system energetics as the dopant progresses from the surface to the bulk. Our calculations predict that Ti stays on the surface, substitutes for Na, and attracts a large number of H atoms to its vicinity. Molecular dynamics simulations suggest that the most likely product of the Ti-doping is the formation of H-rich TiAl_n (n>1) compounds on the surface, and hint at the mechanism by which Ti enhances the reaction kinetics of NaAlH_4.Comment: 3 pages with 3 postscript figures embedded. Uses REVTEX4 and graphicx macros. More information at http://www.ncnr.nist.gov/staff/taner/alanates