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Study of the Effect of Miniaturization of Milling Machines on the Quality of
the Product Surface

Vazirian, Milad | 2010

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 40450 (08)
  4. University: Sharif University of Technology
  5. Department: Mechanical Engineering
  6. Advisor(s): Akbari, Javad; Movahhedy, Mohammad Reza
  7. Abstract:
  8. Improvements in the technology of manufacturing mechanical parts in recent years, has enabled the manufacturers to produce machine tools in small sizes (installable on a desk) which look like conventional counterparts and are called desk-top size machine tools. One important aspect of machine tools operation is the machined surface integrity. Thus, it is necessary to compare desk-top size machines with their conventional counterparts from this point of view. This comparison is the purpose of this thesis in which “surface error” and “surface roughness” of milling machines as a kind of machine tools are compared between conventional and miniaturized machines. To compare the surface errors, static deflection of the machine and tool is calculated. Introducing formulae, static deflection of the tool is separated from the machine and the effect of miniaturization is specified using dimensional analysis. In order to compare the roughnesses, the vibrational amplitude of the tool tip is considered as the factor which increases the roughness. To do this, the frequency response at the tool holder tip is measured and the frequency response of the tool is calculated separately by modeling. Using dimensional analysis, the effect of miniaturization on the machine frequency response at the tool holder tip is calculated and then coupled to the tool response by receptance coupling to investigate the effect of miniaturization on the vibrational amplitude of the tool tip. For using dimensional analysis, it is assumed that the machine parts are rigidly connected to each other and the machine behavior is linear. The analytical results show that both the error and roughness of a surface machined by a desk-top size milling machine are higher than those of a surface machined by a conventional milling machine. In order to do an experimental research, the spindle holder of a milling machine is produced in two large and small sizes and milling tests are conducted on specimens using both spindle holders separately and the roughness of the machined surfaces are compared.
  9. Keywords:
  10. Surface Roughness ; Dimentional Analysis ; Desk-Top Size Machines ; Machine Tools Miniaturization ; Surface Error ; Receptance Coupling

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