A Study on Improving the Machining Performance of Scrolls
Round 1
Reviewer 1 Report
The paper is presented in the required quality. Some comments to improve some parts.
- The quality of Fig. 2,4 and 14 should be improved.
- Indicate directions for further research or implementation of the presented results.
Author Response
Reviewer #1:
The paper is presented in the required quality. Some comments to improve some parts.
- The quality of Fig. 2,4, and 14 should be improved.
Our responses:
According to the reviewer’s comment and suggestion, we have improved the quality of Figs. 2, 4, and 14.
- Indicate directions for further research or implementation of the presented results.
Our responses:
In the section on conclusions, we add the following sentence at the end of the last paragraph: “Further research, which develops a series of feedforward compensation algorithms to modify tool paths before machining processes, is under preparation for submission”.
Reviewer 2 Report
Interesting article, for further research, authors may use two microphones approach. In this research, An Audio-Technica AT9942 microphone has been used. Does the quality or brand of the microphone significantly effects the results?
Author Response
Reviewer #2:
Interesting article, for further research, authors may use two microphones approach. In this research, an Audio-Technica AT9942 microphone has been used. Does the quality or brand of the microphone significantly affects the results?
Our responses:
We sincerely thank the reviewer for his appreciation of our article. On page 5, next to the first sentence of the first paragraph, we add the following sentences: “A general microphone is sufficient for the experiments since the monitored chatter frequency is around 2300 Hz. Besides, a line-directional microphone is chosen to minimize the effects of environmental noise”.
Reviewer 3 Report
Improving the machining efficiency and product precision represents a principle that must be updated as often as possible. This study conducts three adaptive milling processes, which comprise the adaptive feed rate planning, suppression measures, and optimization of milling parameters during scrolls’ rough, semi-fine, and fine machining processes. Please take into account the following observations to improve the reader's perception of the results obtained.
1. The introduction is very well structured and introduces you to the field of machining parameters and makes you understand what the article is trying to achieve.
2. It is not clear whether The flow chart of the PC-based program for chatter suppression was made by the authors or is taken from the bibliography. If it is original, please present a figure with the experimental test used.
3. In line 246, please remove the reference to Tongtai Company because we should not advertise some companies (another: Pro-micron GmbH).
4. Specify the mechanical properties of the aluminum-magnesium alloy Al6061 so that the results obtained from the research for harder or less hard materials can be easily verified.
5. It would have been interesting to add a picture of the semi-finished product, in figure 6.
6. Please specify a table with the stages of the technological film for making a scroll workpiece from the raw material.
7. Figure 16 must also contain a zoom with Scroll workpiece checked.
8. The conclusions should contain exactly the parameters of the milling process that led to the material removal rate by about 14.4% and shorten the cutting time by about 12.6%.
Author Response
Reviewer #3:
Improving the machining efficiency and product precision represents a principle that must be updated as often as possible. This study conducts three adaptive milling processes, which comprise the adaptive feed rate planning, suppression measures, and optimization of milling parameters during scrolls’ rough, semi-fine, and fine machining processes. Please take into account the following observations to improve the reader's perception of the results obtained.
- The introduction is very well structured and introduces you to the field of machining parameters and makes you understand what the article is trying to achieve.
Our responses:
We sincerely thank the reviewer for his appreciation of our article.
- It is not clear whether the flow chart of the PC-based program for chatter suppression was made by the authors or is taken from the bibliography. If it is original, please present a figure with the experimental test used.
Our responses:
We originally developed the PC-based program and its flow chart, and the test results of their validity can be observed in Figs. 4 and 14.
- In line 246, please remove the reference to Tongtai Company because we should not advertise some companies (another: Pro-micron GmbH).
Our responses:
According to the reviewer’s comment and suggestion, we have removed the references to Tongtai Company and Pro-micron GmbH. On page 7, section 5, the first sentence of the first paragraph is amended as: “Figure 6 shows the vertical milling machine utilized in this study to implement the experiments about testing the methods interpreted in the previous sections. On page 8, section 5.1, we delete the fourth sentence entirely, i.e., “This tool holder is the smart tool control system Spike® from Pro-micron GmbH, and its dimension can be customized”.
- Specify the mechanical properties of the aluminum-magnesium alloy Al6061 so that the results obtained from the research for harder or less hard materials can be easily verified.
Our responses:
On page 8, at the end of the first paragraph of section 5, we add the following sentence: “The maximum tensile strength of Al6061 is 150 MPa, and the maximum yield strength is 83 MPa”.
- It would have been interesting to add a picture of the semi-finished product, in figure 6.
Our responses:
On page 22, below the section of conclusions, We add a section of “Supplementary Materials: The following supporting information about the videos of machining processes of the scroll and measuring its profile errors can be downloaded at: www.mdpi.com/xxx/s1, Video S1: Scroll machining processes; Video S2: Profile errors measuring processes”. The semi-finished product can be observed in Video S1: Scroll machining processes.
- Please specify a table with the stages of the technological film for making a scroll workpiece from the raw material.
Our responses:
On page 22, below the section of conclusions, We add a section of “Supplementary Materials: The following supporting information about the videos of machining processes of the scroll and measuring its profile errors can be downloaded at: www.mdpi.com/xxx/s1, Video S1: Scroll machining processes; Video S2: Profile errors measuring processes”. The technological film can be observed in Video S1: Scroll machining processes.
- Figure 16 must also contain a zoom with scroll workpiece checked.
Our responses:
On page 22, below the section of conclusions, We add a section of “Supplementary Materials: The following supporting information about the videos of machining processes of the scroll and measuring its profile errors can be downloaded at: www.mdpi.com/xxx/s1, Video S1: Scroll machining processes; Video S2: Profile errors measuring processes”. The scroll workpiece checks can be observed in Video S2: Profile errors measuring processes.
- The conclusions should contain exactly the parameters of the milling process that led to the material removal rate by about 14.4% and shorten the cutting time by about 12.6%.
Our responses:
On page 21, the section of conclusions, our achievement 1 is amended as: “The method of adaptive feed rate planning can increase the material removal rate by about 14.4% and shorten the cutting time by about 12.6% under the following major machining parameters: the spindle speed of 6000 rpm, the cutting area per cutter tooth of 0.5 mm2, the maximum feed rate limit of 1000 mm/min, and the maximum bending moment of 26.62 Nm”.
