Modeling the effects of Undeformed Chip Volume (UCV) on residual stresses during the milling of curved thin-walled parts

Jiang, Xiaohui; Kong, Xiangjing; Zhang, Zhenya; Wu, Zihui; Zhou, Ding; Guo, Miaoxian

doi:10.1016/j.ijmecsci.2019.105162

Cited by 54 publications

(14 citation statements)

References 28 publications

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“…At present, in the field of milling thin-walled parts, adjusting cutting process parameters is often used to enhance the stiffness of the process system. FEA software was used by Wang et al 6 and Jiang et al 7 to research the influence of machining parameters on redistribution of residual stress of workpiece by combining simulation and experiment. It is found that appropriately increasing cutting speeds 8 and matching with smaller depth of cut can ensure milling efficiency and surface quality.…”

Section: Introductionmentioning

confidence: 99%

Improvement of Surface Quality based on Magnetorheological Fluids Flexible Fixture During Milling Thin-walled Parts

Zhang

Gao

Yang

et al. 2021

Preprint

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Aerospace thin-walled parts have the characteristics of low stiffness and complex structure, which are easily deformed by machine tool vibration, cutting force and heat during machining. The traditional fixture is in point contact with the workpiece, and the workpiece bears uneven force, which results in poor surface quality and low precision of the part. Therefore, it is urgent to improve the machining efficiency and surface quality of workpiece. According to the performance of magnetorheological fluid, a magnetorheological flexible fixture is designed to completely wrap the parts so as to make them bear uniform force, improve the stiffness of the system and inhibit flutter. Firstly, the stiffness distribution of thin-walled parts, flexible fixtures and fixture-workpiece system is studied in this paper. It can be seen that the symmetrical center stiffness of magnetorheological flexible fixtures is relatively low. Through milling experiments with single process parameters, it is found that when the rotational speed, cutting depth and feed speed change, the composite clamping effect is better than the traditional clamping effect, in which with the increase of rotational speed, the vibration acceleration in Ax, Ay and Az directions decreases by 25.16%, 26.87% and 10.78% respectively; When the cutting depth increases, Ay decreases by 23.12% at the maximum. When the feed speed changes, it decreases by 15.78%. Finally, based on the case of milling thin-walled parts with magnetorheological flexible fixture, it is obtained that the coaxiality of composite clamped thin-walled parts decreases by 13.85%, and the maximum decrease of cylindricity is 36.73%. Roughness value Rz decreases by 80.47% at the maximum. In summary, the above results have verified that the machining quality of the magnetorheological flexible fixture is better.

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Section: Introductionmentioning

confidence: 99%

Improvement of Surface Quality based on Magnetorheological Fluids Flexible Fixture During Milling Thin-walled Parts

Zhang

Gao

Yang

et al. 2021

Preprint

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“…The study of geometric parameters on the toroidal part is aimed at analysing the actual geometric configuration of the cutter's end part without thinning on the rake surface in order to identify the possibility of increasing the structural strength of the cutting edge and EPJ Web of Conferences 224, 05001 (2019) https://doi.org/10.1051/epjconf/201922405001 MNPS-2019 the creating the cutting part with an optimal values of the rake angles in all normal sections to the cutting edge on the toroidal surface [16][17][18][19][20][21].…”

Section: Introductionmentioning

confidence: 99%

Design of Toroid-Shaped Solid Ceramic End Mill

et al. 2019

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Electrical discharge machining (EDM) is one of the most accurate methods for machining conductive materials and has a number of important applications. In the EDM process the occurrence of electric charges between cathode and anode is accompanied by vibroacoustic signals, which can be used to develop highly efficient control and diagnostics systems. Experimental studies and modelling of the dynamic system of the EDM process carried out in this study show that parameters of acoustic signals can be used to estimate the current productivity and risks of the tool-electrode breakage and to optimize the tool feed rate. The obtained results of allows using acoustic signals in the control system of the tool electrode feed rate to prevent its breakage, and also setting the interelectrode gap to maximum productivity.

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“…Nespor et al [19] compared the residual stress state after processing ti-6al-4v with composite ball head milling method and orthogonal cutting method, and the results showed that only when the shape of workpiece and the subsurface deformation shape determined by tool motion were considered, the residual stress would be transferred to the subsurface. Jiang et al [20] proposed a mathematical model between the curved surface maximum tensile residual stress and the Undeformed Chip Volume (UCV) (fz, R, ap and ae) of the ball end milling cutter. This mathematical model can quantify the influences of machining parameters on maximum tensile residual stress during the milling of Al2024 parts.…”

Section: Introductionmentioning

confidence: 99%

Effects of Milling Parameters on Distribution of Residual Stress During the Milling of Curved Thin-Walled Parts

Kong

Zhou

Xu³

et al. 2019

EPJ Web Conf.

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With the increasing application of curved thin-walled parts, the evaluation and control of curved surface residual stress in milling are becoming increasingly demanding. However, effects of milling parameters on distribution of residual stress remains a major challenge in the present aerospace research areas. In this paper, , impacts of milling parameters on curved surface residual stress have been investigated in a series of residual stress experiments and simulations. It is found that the residual stress can be lowered by increasing milling speed and tool radius within a reasonable range. The superposition of curved surface residual stress under two machining conditions have been analyzed using the milling simulation model. It has been found that the curved surface residual stress induced by the subsequent cutting will be superimposed on the curved surface residual stress induced by the previous cutting and that the superposition rates of residual stress induced by up milling are larger than down milling.

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Modeling the effects of Undeformed Chip Volume (UCV) on residual stresses during the milling of curved thin-walled parts

Cited by 54 publications

References 28 publications

Improvement of Surface Quality based on Magnetorheological Fluids Flexible Fixture During Milling Thin-walled Parts

Improvement of Surface Quality based on Magnetorheological Fluids Flexible Fixture During Milling Thin-walled Parts

Design of Toroid-Shaped Solid Ceramic End Mill

Effects of Milling Parameters on Distribution of Residual Stress During the Milling of Curved Thin-Walled Parts

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