Researcher:
Erdim, Hüseyin

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PhD Student

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Hüseyin

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Erdim

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Erdim, Hüseyin

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2006 - 20073

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    Feedrate scheduling strategies for free-form surfaces
    (Elsevier Sci Ltd, 2006) N/A; Department of Mechanical Engineering; N/A; Erdim, Hüseyin; Lazoğlu, İsmail; Öztürk, Burak; PhD Student; Faculty Member; N/A; Department of Mechanical Engineering; Graduate School of Sciences and Engineering; College of Engineering; N/A; N/A; 179391; N/A
    Free-form machining is one of the commonly used manufacturing processes for several industries such as automobile, aerospace, die and mold industries. In 3D complicated free-form surfaces, it is critical, but often difficult, to select applicable cutting conditions to achieve high productivity while maintaining high quality of parts. It is essential to optimize the feedrate in order to improve the machining efficiency of the ball-end milling. Conservative constant feedrate values have been mostly used up to now since there was a lock of physical models and optimization tools for the machining processes. The common approach used in feedrate scheduling is material removal rate (MRR) model. In the MRR based approach, feedrate is inversely proportional to either average or instantaneous volumetric removal rate. Commonly used CAM programs and NC code generators based on only the geometric and volumetric analysis, but they do not concern the physics of the free-form machining process yet. The new approach that is also introduced in this paper is based on the mechanics of the process. In other words, the force-based models in which feedrate is set to values which keep either average or instantaneous machining forces to prescribed values. In this study, both feedrate scheduling strategies are compared theoretically and experimentally for 3D ball-end milling of free-form surfaces. It is shown that MRR based feedrate strategy outputs higher feedrate values compared to force based feedrate strategy. High feedrate values of the MRR strategy increase the cutting forces extensively which can be damaging to the part quality and to the CNC Machine. When the new force based feedrate-scheduling strategy introduced in this paper is used, it is shown that the machining time can be decreased significantly along the tool path. The force-based feedrate scheduling strategy is tested under various cutting conditions and some of the results are presented in the paper. (C) 2005 Elsevier Ltd. All rights reserved.
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    Machining of free-form surfaces. Part II: calibration and forces
    (Elsevier Sci Ltd, 2006) N/A; N/A; Department of Mechanical Engineering; N/A; Lazoğlu, İsmail; Öztürk, Burak; Erdim, Hüseyin; Master Student; Faculty Member; PhD Student; Department of Mechanical Engineering; Manufacturing and Automation Research Center (MARC); Graduate School of Sciences and Engineering; College of Engineering; Graduate School of Sciences and Engineering; N/A; 179391; N/A
    in the machining simulations of 3D free-form surfaces by ball-end milling, calibration coefficients play very critical role in force predictions. in other words, obtaining the calibration coefficients from calibration tests is a very influential process in the prediction of cutting forces. accurately obtained calibration coefficients lead to better force predictions. in the literature, the calibration coefficients are assumed to be independent of start and exit angles of the engagement region, thus they are assumed to be identical for any engagement region. Calibration coefficients are obtained from the horizontal slot cutting tests and these tests are repeated for different depth of cuts. in this paper, in order to achieve, more accurate force predictions in free-form machining simulations, A new modification algorithm for calibration coefficients is presented. in this research, with theoretical analysis and experimental force signals, it is shown that the inclination angle has a great importance in calibration and in force simulation of 3D free-form machining.
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    Free-form surface machining and comparing feedrate scheduling strategies
    (Taylor & Francis Inc, 2007) N/A; Department of Mechanical Engineering; N/A; Erdim, Hüseyin; Lazoğlu, İsmail; Kaymakçı, Mustafa; PhD Student; Faculty Member; Master Student; Department of Mechanical Engineering; Graduate School of Sciences and Engineering; College of Engineering; Graduate School of Sciences and Engineering; N/A; 179391; N/A
    This article presents mathematical models of cutting forces and surface-form errors for machining of free-form surfaces. Besides the predictive models of cutting forces and surface deflections, a newly developed force based feedrate scheduling (FFS) technique is compared with material removal rate (MRR) based feedrate scheduling method that was used in feedrate optimization packages. With the experimental validations in free-farm surfaces, it is shown that the mechanic models predict the forces and surface-form errors quite well. Moreover, by modifying the CNC programs with the new FFS technique, cycle times of the free-form parts can be decreased significantly.