Details
| Original language | English |
|---|---|
| Title of host publication | European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022 |
| Editors | Richard K. Leach, A. Akrofi-Ayesu, C. Nisbet, Dishi Phillips |
| Pages | 505-508 |
| Number of pages | 4 |
| ISBN (electronic) | 9781998999118 |
| Publication status | Published - 2022 |
| Event | 22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022 - Geneva, Switzerland Duration: 30 May 2022 → 3 Jun 2022 |
Publication series
| Name | European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022 |
|---|
Abstract
High speed cutting offers the possibility to significantly speed up diamond milling processes. It not only increases the economic efficiency but also has a positive impact on the material removal mechanisms and the resulting tool wear. Electromagnetic feed axes provide the potential to enable the required precision and reduction of vibration at the increased feed velocities and axis dynamics. This paper comprises first results obtained by combining diamond fly-cutting on a high-speed air bearing spindle with an electromagnetic feed axis on a custom-built 3-axis machining setup. After balancing the spindle with a fly-cut-head (Dfly= 160 mm), two sets of experiments were conducted: first, the cutting speed was varied by setting the respective spindle speed between n = 4,000 and 7,500 min-1(i.e. vc= 33 to 63 m·s-1). During these runs, the feed velocity was adapted to maintain a theoretical surface roughness of Rkin= 10 nm. In the second set of experiments, the feed velocity was varied for a constant spindle speed of n = 7,500 min-1between vf= 600 mm·min-1and 4,800 mm·min-1in order to observe the behaviour of the magnetic axis at very high speeds. In both cases, live data (e.g. axis position/velocity/acceleration) was captured during machining and measurements of the machined surface were taken by coherence scanning interferometry. The results show that the setup including the magnetically levitated axis is capable of producing high precision surfaces with sub-40 nm RMS surface roughness. No significant deterioration of the performance at high feed velocities is observed. However, deviation occurring at higher speeds tend to affect long-wave surface features, i.e. the waviness.
Keywords
- diamond milling, high performance cutting, magnetically levitated feed axis
ASJC Scopus subject areas
- Engineering(all)
- Industrial and Manufacturing Engineering
- Engineering(all)
- Mechanical Engineering
- Environmental Science(all)
- Environmental Engineering
- Materials Science(all)
- General Materials Science
- Physics and Astronomy(all)
- Instrumentation
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European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. ed. / Richard K. Leach; A. Akrofi-Ayesu; C. Nisbet; Dishi Phillips. 2022. p. 505-508 (European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022).
Research output: Chapter in book/report/conference proceeding › Conference contribution › Research › peer review
}
TY - GEN
T1 - Ultra-precision high performance cutting of nickel silver using a magnetically levitated feed axis
AU - Schönemann, Lars
AU - Dörgeloh, Timo
AU - Riemer, Oltmann
AU - Schreiber, Per
AU - Klemme, Heinrich
AU - Denkena, Berend
N1 - Funding Information: The authors would like to thank the German Research Foundation (DFG) for funding this work as part of the Research Unit FOR 1845 "Ultra-precision High Performance Cutting".
PY - 2022
Y1 - 2022
N2 - High speed cutting offers the possibility to significantly speed up diamond milling processes. It not only increases the economic efficiency but also has a positive impact on the material removal mechanisms and the resulting tool wear. Electromagnetic feed axes provide the potential to enable the required precision and reduction of vibration at the increased feed velocities and axis dynamics. This paper comprises first results obtained by combining diamond fly-cutting on a high-speed air bearing spindle with an electromagnetic feed axis on a custom-built 3-axis machining setup. After balancing the spindle with a fly-cut-head (Dfly= 160 mm), two sets of experiments were conducted: first, the cutting speed was varied by setting the respective spindle speed between n = 4,000 and 7,500 min-1(i.e. vc= 33 to 63 m·s-1). During these runs, the feed velocity was adapted to maintain a theoretical surface roughness of Rkin= 10 nm. In the second set of experiments, the feed velocity was varied for a constant spindle speed of n = 7,500 min-1between vf= 600 mm·min-1and 4,800 mm·min-1in order to observe the behaviour of the magnetic axis at very high speeds. In both cases, live data (e.g. axis position/velocity/acceleration) was captured during machining and measurements of the machined surface were taken by coherence scanning interferometry. The results show that the setup including the magnetically levitated axis is capable of producing high precision surfaces with sub-40 nm RMS surface roughness. No significant deterioration of the performance at high feed velocities is observed. However, deviation occurring at higher speeds tend to affect long-wave surface features, i.e. the waviness.
AB - High speed cutting offers the possibility to significantly speed up diamond milling processes. It not only increases the economic efficiency but also has a positive impact on the material removal mechanisms and the resulting tool wear. Electromagnetic feed axes provide the potential to enable the required precision and reduction of vibration at the increased feed velocities and axis dynamics. This paper comprises first results obtained by combining diamond fly-cutting on a high-speed air bearing spindle with an electromagnetic feed axis on a custom-built 3-axis machining setup. After balancing the spindle with a fly-cut-head (Dfly= 160 mm), two sets of experiments were conducted: first, the cutting speed was varied by setting the respective spindle speed between n = 4,000 and 7,500 min-1(i.e. vc= 33 to 63 m·s-1). During these runs, the feed velocity was adapted to maintain a theoretical surface roughness of Rkin= 10 nm. In the second set of experiments, the feed velocity was varied for a constant spindle speed of n = 7,500 min-1between vf= 600 mm·min-1and 4,800 mm·min-1in order to observe the behaviour of the magnetic axis at very high speeds. In both cases, live data (e.g. axis position/velocity/acceleration) was captured during machining and measurements of the machined surface were taken by coherence scanning interferometry. The results show that the setup including the magnetically levitated axis is capable of producing high precision surfaces with sub-40 nm RMS surface roughness. No significant deterioration of the performance at high feed velocities is observed. However, deviation occurring at higher speeds tend to affect long-wave surface features, i.e. the waviness.
KW - diamond milling
KW - high performance cutting
KW - magnetically levitated feed axis
UR - http://www.scopus.com/inward/record.url?scp=85145588479&partnerID=8YFLogxK
M3 - Conference contribution
AN - SCOPUS:85145588479
T3 - European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022
SP - 505
EP - 508
BT - European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022
A2 - Leach, Richard K.
A2 - Akrofi-Ayesu, A.
A2 - Nisbet, C.
A2 - Phillips, Dishi
T2 - 22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022
Y2 - 30 May 2022 through 3 June 2022
ER -