Software enables 'thoroughly modern milling'

Sep 04, 2007
Software enables 'thoroughly modern milling'
Software developed using a concept discovered at WUSTL may be used to optimize high-speed machining processes, leading to lighter, stronger, and more accurate parts for the aircraft or medical device industry. Credit: WUSTL

An engineer at Washington University in St. Louis has helped find a way to "cut the chatter" in high-speed machining of aluminum and titanium aircraft parts.

Chatter in milling is an instability that arises because the cutting tool vibrates, making oscillating patterns on the work piece. The tool goes over the patterns, making the tool vibrate even more, yielding deeper patterns in the work piece, worsening until eventually the chatter destroys the tool or work piece.

Now researchers including Philip V. Bayly, Ph.D., Washington University Hughes Professor of Mechanical Engineering, and Washington University alumnus Jerry Halley, of Tech Manufacturing, Wright City, Missouri, have developed software that predicts when chatter is going to occur as well as the accuracy of the cut. The software is based on a technique called time finite element analysis (TFEA).

Avoiding chatter allows much faster machining, makes the tool last longer, and increases the quality of the parts. Lighter, stronger, and more accurate parts lead to faster, more durable, and more affordable aircraft.

"This analytical technique helps get accurate machining processes and can play a major role in businesses creating higher quality parts that are less costly to make," said Bayly. "You can get a big pay off in stability and accuracy just by changing the speed at which the tools cut. That's one of the key things that TFEA finds out."

TFEA simulations are performed before the milling process, using a computer model of the machining system. The analysis predicts good and bad speeds for stability and accuracy of the cuts.

Bayly and several colleagues have applied for a patent on a concept that will take advantage of TFEA to design machining processes. The computations can be done so speedily that the hope is that the software will be used widely in advanced aerospace, automotive, and medical machine shops.

Source: Washington University in St. Louis

Explore further: Revealing faded frescos

Related Stories

Bringing 'common sense' to text analytics

Sep 26, 2013

Bringing "common sense" to artificial intelligence is one of the biggest challenges in computer science: It entails equipping computers with the shared knowledge that humans use to infer meaning, make connections ...

Social media tools can boost productivity

Aug 14, 2012

In this digital age, U.S. physicians still send and receive some 15 billion faxes a year. But not Dr. Howard Luks, chief of sports medicine and knee replacements at Westchester Medical Center in Valhalla, N.Y.

Google Dart debut sparks chatter of JavaScript coup

Oct 12, 2011

(PhysOrg.com) -- When the news appeared earlier this week that Google was unveiling a new programming language, Dart, for developers. tech blogs ignited with talk of how Google is staging a JavaScript coup. ...

Recommended for you

Revealing faded frescos

6 hours ago

Many details of the wall and ceiling frescos in the cloister of Brandenburg Cathedral have faded: Plaster on which horses once "galloped" appears more or less bare. A hyperspectral camera sees images that remain hidden to ...

Device could detect driver drowsiness, make roads safer

7 hours ago

Drowsy driving injures and kills thousands of people in the United States each year. A device being developed by Vigo Technologies Inc., in collaboration with Wichita State University professor Jibo He and ...

New capability takes sensor fabrication to a new level

Jun 30, 2015

Operators must continually monitor conditions in power plants to assure they are operating safely and efficiently. Researchers on the Sensors and Controls Team at DOE's National Energy Technology Laboratory ...

Smart phones spot tired drivers

Jun 30, 2015

An electronic accelerometer of the kind found in most smart phones that let the device determine its orientation and respond to movement, could also be used to save lives on our roads, according to research ...

User comments : 0

Please sign in to add a comment. Registration is free, and takes less than a minute. Read more

Click here to reset your password.
Sign in to get notified via email when new comments are made.