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Computer simulation of industrial processes is an important alternative that may be used either to complement or to replace expensive experimental procedures associated with developing new parts or modifying existing process. For a metal cutting process, numerical simulations provide vital information about cutting forces, cutting temperatures, tooling and part distortion, etc. Since the early 1970s, FEA has been applied to simulate machining process. The development of this approach, its assumptions and techniques has been widely accepted. Nowadays, the manufacturing productivity even drives the community to the next level innovation through computer utilizations. A kinematic simulation of machining processes is one of many innovative CAE applications, especially beneficial to high volume production of automotive powertrain parts. In this paper, a generic force calculation method is introduced with a modified horsepower correction factor. An example of sizing milling force, milling paths and proper milling parameters is provided by utilizing the methodology. This paper will also discuss and propose how the manufacturing industry uses this resourceful tool. Applications of the methodology would empower product and manufacturing engineers to make intelligent and cost effective decisions.

In the automotive industry, sealing quality between two flat joint surfaces is directly affected by the surface flatness. To know how much flatness is caused by machining operations, a traditional trial-and-error method has been used. The prediction for machined surface error/distortion can help to assess the integrity of the structural design as well as develop fixturing scheme to optimize machining quality. In this paper, a finite element method is applied to extract the compliance matrix of milling surface of a workpiece, such as the cylinder deck face, and an encoding MatLab program is used to compute the flatness due to milling forces. The paper focuses on deriving analytical models for evaluating the flatness of the cylinder deck face and optimizing the manufacturing process. Some special considerations have been taken to manufacturing cutting force evaluations according to analysis results of the deck face flatness. Emphasis is also placed on the optimization of machining parameters by iterations of flatness results so that minimization of surface deformations under machining loads can be achieved. The methodology introduced in the paper is the closed-loop iteration by combining structural finite element analysis (FEA) simulation, tooling kinematic simulation, and MatLab data modeling.

Graphene oxide (GO)-doped CFRP composites possess excellent mechanical properties for high-performance products of aircraft, defense, biomedical and chemical trades. This paper highlights a novel hybridization of the combined compromise solution-principal component analysis (CoCoSo-PCA) method to optimize multiple correlated responses during CNC milling of GO-doped epoxy/CFRP. The influence of process constraints like drill speed ($S$), feed rate ($F$), Depth of cut ($D$) and GO wt.% (GO) on machining performances like MRR, cutting force ($F_c$) and Surface roughness ($Ra$) has investigated. Taguchi $L_9$ orthogonal array considered for machining (milling) of composite by using Titanium aluminium nitride (TiAlN) milling cutter ($\varphi 5$mm). A multivariate hybrid approach based on combined multiplication rule was utilized to evaluate the ranking of the alternatives decision process and optimize responses. ANOVA reveals that spindle speed (82.24%) is the most influential factor trailed by feed rate (5.02%), depth of cut (0.55%) and GO wt.% (2.17%). This module has fruitfully tackled critical issues such as response priority weight assignment and response correlation. Finally, CoCoSo-PCA shows the higher predicted value of 9.06 and confirmatory test performed on optimum settings as $S-1600$ RPM, $F$-160mm/rev $D-0.5$mm and GO-1%, which show a satisfactory agreement with actual ones for favorable machining environment.

Measuring the circular passes and errors of the periodic milling tools holder is of paramount importance for ensuring excellent surface roughness. For rendering circular shapes during a milling process, a circular interpolation to measure circular passes and errors of the periodic cutting tools holder is thus used. This model is intended to complement the computerized numerically controlled (CNC) systems. The model contains a number of blocks, such as a complete circular interpolation cycle of a number passes which is specified in the programmable part of the model. This study presents a new localization approach for an elastic cutting tool holder of a milling machine. A numerical model is developed that describes the structure of the tool holder. The behavior of the periodic holder is modeled numerically. The modeling results are in agreement with the experimental measurements with a relative error of about 8%.