Modeling, Simulation and Compensation of Thermomechanically Induced Material Deformation in Dry NC Milling Processes

Siebrecht, Tobias; Wiederkehr, Petra; Zabel, Andreas; Schweinoch, Matthias; Byfut, A.; Schröder, Jörg

doi:10.1007/978-3-319-57120-1_13

Cited by 2 publications

(3 citation statements)

References 38 publications

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“…The following numerical simulation is chosen to resemble an actual physical experiment pursued in Siebrecht et al For that experiment, a cuboidal workpiece composed of the aluminium alloy AL7075 with edge lengths 70, 70, and 20 mm is considered, see Figure A. In the following, we assume a reference coordinate system, so that the initial workpiece is given by

\hat{normalΩ} = {normalΩ}_{0} : = {(- 35 mm, 35 mm)}^{2} \times (- 10 mm, 10 mm) .

The workpiece itself is clamped in a bench vise on

\begin{matrix} \partial Ω_{0} \cap true(false[- 35 mm, 35 mm false] \times false[- 35 mm, - 30 mm false] \times false[- 10 mm, - 5 mm false] \cup \\ false[- 35 mm, 35 mm false] \times false[30 mm, 35 mm false] \times false[- 10 mm, - 5 mm false] true) \end{matrix}

as depicted in Figure B.…”

Section: Numerical Simulationmentioning

confidence: 99%

“…The resulting steps can be seen in Figure C,D, respectively. After the cool down of the workpiece, measurements of the pocket width as well as of the width of the milled steps were taken using a digital microscope and a contour measurement device as described in Siebrecht et al The measured width of the upper half of the pocket is approximately 60.752 mm. Comparing this to the expected width of 61mm and assuming an evenly distributed milling error for both sides of the pocket, we conclude that each of the opposing pocket walls has bended away 124 μm from one another during the physical experiment.…”

Section: Numerical Simulationmentioning

confidence: 99%

“…Images of the physical experiment pursued in Siebrecht et al Figure A depicts the initial workpiece. In Figure B, this workpiece is clamped in the bench vise and equipped with temperature sensors.…”

Section: Numerical Simulationmentioning

confidence: 99%

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A fictitious domain method for the simulation of thermoelastic deformations in NC‐milling processes

Byfut

Schröder

2017

Numerical Meth Engineering

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Summary This paper presents a (higher‐order) finite element approach for the simulation of heat diffusion and thermoelastic deformations in NC‐milling processes. The inherent continuous material removal in the process of the simulation is taken into account via continuous removal‐dependent refinements of a paraxial hexahedron base‐mesh covering a given workpiece. These refinements rely on isotropic bisections of these hexahedrons along with subdivisions of the latter into tetrahedrons and pyramids in correspondence to a milling surface triangulation obtained from the application of the marching cubes algorithm. The resulting mesh is used for an element‐wise defined characteristic function for the milling‐dependent workpiece within that paraxial hexahedron base‐mesh. Using this characteristic function, a (higher‐order) fictitious domain method is used to compute the heat diffusion and thermoelastic deformations, where the corresponding ansatz spaces are defined for some hexahedron‐based refinement of the base‐mesh. Numerical experiments compared to real physical experiments exhibit the applicability of the proposed approach to predict deviations of the milled workpiece from its designed shape because of thermoelastic deformations in the process.

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