BITS Faculty Publications
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Item An Investigation Of Surface Errors In Thin-Walled Machining(i-Manager, 2012) Bera, T.C.Prediction of surface errors in milling of thin-walled structures is not trivial due to cutting force induced deflections of workpiece. The situation becomes more complicated when the end mill adds cutter deflection errors to workpiece deflection. It is important to predict and analyze such variation of surface error from process planning and process control point of view. The study of surface error is also essential while overcoming the same by applying various compensation methods. This paper investigates cutter and workpiece deflection induced surface errors in peripheral milling of thin-walled straight and curved geometries. A flexible tool-workpiece system has been developed to estimate surface error in the presence of both tool and workpiece deflections. The effects of chip load and workpiece curvature on surface errors have also been investigated by using experimental and computational methodology. Based on the outcomes of the present study, it is concluded that the complex nature of tool and workpiece deflection induced surface error can be predicted both qualitatively and quantitatively in thin-walled machining. The results presented here provide useful insights into qualitative and quantitative nature of surface errors which will be helpful for product designers as well as process planners in improving machining productivity without sacrificing quality.Item Developing Energy Efficient Milling Strategy for Variable Curved Geometry Using Constant Engagement Method(Elsevier, 2023) Sangwan, Kuldip Singh; Bera, T.C.The continuous fluctuation in force profile in milling of variable curved geometry creates a barrier in stable machining and in cutting power consumption. The fluctuation in force profile happens due to alteration in chip load in the presence of workpiece curvature. The present study aims to develop an energy efficient machining strategy for milling of variable curved geometries where more uniform cutting force and cutting power consumption profiles are accomplished due to constant chip load along the peripheral length of curved geometry. The proposed strategy involves mechanics of milling, instantaneous cutting force and cutting power consumption. It is formulated based on constant chip load by regulating entry angle of milling cutter according to workpiece curvature along the peripheral length. Thus, the cutting power fluctuation that is occurred due to variation of workpiece curvature is reduced by regulating tool-workpiece engagement. The energy consumption is reduced almost 18 % using the proposed approach. It results into developing an energy efficient machining strategy for milling of variable curved geometry. It also provides stable machining process and increased tool life by reducing tool wear due to reduction of force fluctuation during metal removal process.