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: New ultrasound device may add in detecting risk for heart attack, stroke

add to favorites email to friend print save as pdf

Related Stories

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. ...

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.

Recommended for you

A smart prosthetic knee with in-vivo diagnoses

Apr 22, 2014

The task was to develop intelligent prosthetic joints that, via sensors, are capable of detecting early failure long before a patient suffers. EPFL researchers have taken up the challenge.

User comments : 0

More news stories

New breast cancer imaging method promising

The new PAMmography method for imaging breast cancer developed by the University of Twente's MIRA research institute and the Medisch Spectrum Twente hospital appears to be a promising new method that could ...

Research proves nanobubbles are superstable

The intense research interest in surface nanobubbles arises from their potential applications in microfluidics and the scientific challenge for controlling their fundamental physical properties. One of the ...

Using antineutrinos to monitor nuclear reactors

When monitoring nuclear reactors, the International Atomic Energy Agency has to rely on input given by the operators. In the future, antineutrino detectors may provide an additional option for monitoring. ...