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Optimum CNC Free-form Surface Machining Through Design of Experiments in CAM Software

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Modern Mechanical Engineering

Part of the book series: Materials Forming, Machining and Tribology ((MFMT))

Abstract

Sculptured surface machining (SSM) is an operation widely applied to several industrial fields such as aerospace, automotive and mold/die. The number of the parameters and strategies involved to program such machining operations can be enormously large owing to surface complexity and advanced design features. To properly reduce the number of parameters, design of experiments (DOE) methodology along with statistical analysis can be adopted. In this paper DOE and respective analysis were used to conduct machining experiments with the use of a computer aided manufacturing (CAM) software. Major goal is to investigate which of process parameters are worthy of optimization through intelligent systems. Two scenarios were considered to machine a sculptured part; one involving 3-axis roughing/3-axis finish machining experiments and one involving 3-axis roughing/5-axis finish machining experiments. Roughing operation was common for both scenarios. The problem was subjected to discrete technological constraints to reflect the actual industrial status. For each machining phase, two quality objectives reflecting productivity and part quality were determined. Roughing experiments were conducted to minimize machining time (t mr ) and remaining volume (v r ); whilst finishing experiments were targeted to minimize machining time (t mf ) and surface deviation (s dev ) between the designed and the machined 3D model. Quality characteristics were properly weighted to formulate a single objective criterion for both machining phases. Results indicated that DOE applied to CAM software, enables numerical control (NC) programmers to have a clear understanding about the influence of process parameters for sculptured surface machining operations generating thus efficient tool paths to improve productivity, part quality and process efficiency. Practically the work contributes to machining improvement through the proposition of machining experimentation methods using safe and useful platforms such as CAM systems; the application of techniques to avoid problem oversimplification mainly when large number of machining parameters should be exploited and the evaluation of quality criteria which allow their assessment directly from CAM software.

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Author information

Authors and Affiliations

  1. Department of Mechanical Engineering Educators, School of Pedagogical and Technological Education (ASPETE), N. Heraklion, GR, 14121, Athens, Greece

    N. A. Fountas & N. M. Vaxevanidis

  2. Department of Mechanical Engineering, Technological Educational Institute (TEI) of Piraeus, 250 Thivon Str, GR, 12244, Egaleo, Greece

    C. I. Stergiou

  3. Faculty of Science, Engineering and Computing, Kingston University, Penrhyn Road, Kingston Upon Thames, KT1 2EE, UK

    N. A. Fountas & R. Benhadj-Djilali

Authors
  1. N. A. Fountas
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  2. N. M. Vaxevanidis
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  3. C. I. Stergiou
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  4. R. Benhadj-Djilali
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Corresponding author

Correspondence to N. M. Vaxevanidis .

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Editors and Affiliations

  1. Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal

    J. Paulo Davim

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Fountas, N.A., Vaxevanidis, N.M., Stergiou, C.I., Benhadj-Djilali, R. (2014). Optimum CNC Free-form Surface Machining Through Design of Experiments in CAM Software. In: Davim, J. (eds) Modern Mechanical Engineering. Materials Forming, Machining and Tribology. Springer, Berlin, Heidelberg. https://doi.org/10.1007/978-3-642-45176-8_10

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  • DOI: https://doi.org/10.1007/978-3-642-45176-8_10

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  • Publisher Name: Springer, Berlin, Heidelberg

  • Print ISBN: 978-3-642-45175-1

  • Online ISBN: 978-3-642-45176-8

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