Milling error prediction and compensation in machining of low-rigidity parts

Ratchev, Svetan; Liu, Shulong; Huang, Wei; Becker, A.A.

doi:10.1016/j.ijmachtools.2004.06.001

Cited by 205 publications

(88 citation statements)

References 14 publications

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“…A good agreement between the numerical and experimental data shows the validity of the presented FEM-based milling simulation model in handling real-field problems. The main advantages of the presented system over previous works [7,9,[17][18][19] and the traditional computer-aided manufacturing) software [2,23,24] are the following:…”

Section: Discussionmentioning

confidence: 99%

FEM-based prediction of workpiece transient temperature distribution and deformations during milling

Jitender

Xirouchakis

2008

Int J Adv Manuf Technol

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In high-speed dry milling of thin-walled parts, the cutter-workpiece temperature rises asymptotically with cutting speed, causing excessive cutter tooth wear and workpiece thermal expansion, which in turn reduces the cutter life and produces dimensional and geometrical variabilities in the machined part. Therefore, a basic understanding of the thermal aspect of machining and the effecting parameters is essential for achieving better part quality with improved productivity. This paper presents a transient milling simulation model to assist manufacturing engineers in gaining in-depth understanding of the thermomechanical aspects of machining and their influence on resulted part quality. Based on the finite-element method approach, the model can predict transient temperature distributions and resulted elastic-plastic deformations induced during the milling of 2.5D prismatic parts comprising features like slots, steps, pockets, etc. The advantages of the proposed model over previous works are that it (1) performs feature-based machining simulation considering transient thermomechanical loading conditions; (2) allows modeling the effects of coolant on convective heat transfer rate; and (3) considers the nonlinear behavior of the workpiece due to its changing geometry, inelastic material properties, and flexible fixtureworkpiece contacts. The prediction accuracy of the model was validated with experimental results obtained

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Section: Discussionmentioning

confidence: 99%

FEM-based prediction of workpiece transient temperature distribution and deformations during milling

Jitender

Xirouchakis

2008

Int J Adv Manuf Technol

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“…• The geometric model can also be a solid model using Voxels [18], Dexels [19] ( Fig. 25.5) or Triple-Nailboard (Fig.…”

Section: Geometric Model Of the Workpiecementioning

confidence: 99%

Survey on Simulation Methods in Multi-axis Machining

Bouhadja

Bey

2015

Transactions on Engineering Technologies

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In industry, the evolution of productivity and quality of mechanical manufacture of complex shape parts (mold, automobile, form : : : ) is marked by the development of several machining simulation techniques for modeling and predicting the manufacturing process to represent the most realistic cut phenomenon. There exist several machining simulation techniques and touch various levels. Thus, this chapter summarizes the literature review and presents the techniques in a simplified scheme for the rapid exploration in this area, and in order to direct the reader to select an appropriate approach linked to a geometric or physical problem at a given scales in Part-Tool-Machine system. Particular attention is given to geometric simulation methods of the macroscopic scale; completed by brief comparison between models of workpiece representation for material removal process (Dexel, Voxel, Triple-Dexel).

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“…The initial work of applying TFEA to the delay equations can be found in Ref. [5]. The main idea of TFEA is that the dynamic behavior of the milling process is governed by TFEA as a discrete linear map which relates the vibration response while the tool tooth is engaged in the cut, which depends on previous tooth passages and therefore includes the time delay  , to free vibration while the tooth is not engaged in the cut.…”

Section: Deterministic Model For Predicting Milling Stability and Calmentioning

confidence: 99%

“…The direct trial-and-error approach is often expensive and time consuming. Producing the right profile in such parts increasingly depends on specialized CAD/CAE/CAM packages for defining appropriate cutting strategies and tool paths [4][5][6][7]. However, most of the existing techniques and models are based on idealised geometries and do not take into account factors such as variable cutting force, part/tool deflection, machining stability [8].…”

Section: Introductionmentioning

confidence: 99%