Review on Deflection Compensation Methods for Machining of Thin-Walled Components

Chen, Yue Ping; Gao, Jian; Wu, Lifeng

doi:10.4028/www.scientific.net/amm.29-32.1768

Cited by 5 publications

(3 citation statements)

References 30 publications

(60 reference statements)

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“…Zeng et al 7 established a stiffness model for thin-walled parts and designed a special auxiliary fixture based on the stiffness calculation results, and the results showed that this method effectively improved the machining stiffness of thin-walled parts. Chen et al 8 used the method of layered complete compensation and optimized compensation machining path, and established the machining path compensation optimization model, which effectively reduced the machining deformation problem of thin-walled parts. Ge et al 9 used paraffin-assisted fixation of thin-walled parts to improve the stiffness of thin-walled parts to achieve the machining stability of titanium alloy thin-walled parts.…”

Section: Introductionmentioning

confidence: 99%

Study on milling flatness control method for TC4 titanium alloy thin-walled parts under ice fixation

Zhan,

Jin,

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Thin-walled parts are characterized by weak rigidity and are very prone to deformation during machining, which directly affects the machining accuracy and performance of the parts, so controlling the machining deformation of thin-walled parts is an urgent process problem to be solved. To address such problems, this paper proposes a flatness control machining method based on ice holding of workpieces. The method uses frozen suction cups to solidify liquid water to achieve stress-free clamping of workpieces. We conducted a low-temperature tensile test to investigate the low-temperature mechanical properties of the material. Comparative tests of ice-free and low-temperature ice-fixed milling were conducted to compare and analyze the changes of flatness and milling force in the two working conditions, to investigate the influence of machining parameters on the flatness of thin-walled parts, and to reveal the mechanism of low-temperature milling of ice-fixed workpieces. In addition, the low-temperature milling performance of titanium/aluminum alloy based on ice-fixation was compared. The results show that TC4 has good plasticity, high flexural strength ratio and strong resistance to deformation at low temperatures. Compared with no ice-holding, ice-holding machining effectively improves the flatness of the workpiece, and the order of the machining parameters affecting flatness is: feed rate > milling depth > spindle speed. The milling forces under ice-holding conditions were all greater than those without ice holding. The stiffness and hardness, resistance to damage and deformation of titanium alloy at low temperature are greater than those of aluminum alloy. This method provides a new method for high-precision machining of thin-walled parts.

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Section: Introductionmentioning

confidence: 99%

Study on milling flatness control method for TC4 titanium alloy thin-walled parts under ice fixation

Zhan,

Jin,

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…(4) Tool path compensation. As deflections of the cutting tool and the workpiece cause over/undercut, the toolpath points should be adjusted accordingly so that the desired width of cut is obtained 10 . (5) Optimization of the cutting sequence.…”

Section: Introductionmentioning

confidence: 99%

Numerical evaluation of cutting strategies for thin-walled parts

Lassila,

Svensson,

Wang

et al. 2024

Sci Rep

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Static form errors due to in-process deflections is a major concern in flank milling of thin-walled parts. To increase both productivity and part geometric accuracy, there is a need to predict and control these form errors. In this work, a modelling framework for prediction of the cutting force-induced form errors, or thickness errors, during flank milling of a thin-walled workpiece is proposed. The modelled workpiece geometry is continuously updated to account for material removal and the reduced stiffness matrix is calculated for nodes in the engagement zone. The proposed modelling framework is able to predict the resulting thickness errors for a thin-walled plate which is cut on both sides. Several cutting strategies and cut patterns using constant z-level finishing are studied. The modelling framework is used to investigate the effect of different cut patterns, machining allowance, cutting tools and cutting parameters on the resulting thickness errors. The framework is experimentally validated for various cutting sequences and cutting parameters. The predicted thickness errors closely correspond to the experimental results. It is shown from numerical evaluations that the selection of an appropriate cut pattern is crucial in order to reduce the thickness error. Furthermore, it is shown that an increased machining allowance gives a decreased thickness error for thin-walled plates.

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“…The thin-web structure components are widely used in aviation and aerospace industries for the purpose of reducing weight, high performance and increasing efficiency [1][2][3][4]. However, the thinweb components are tending to deflect and deform during machining under the cutting forces and low-rigidity of these components [1][2][3] and seriously affect their machining accuracy and surface quality which persuaded to surface dimensional errors [3,4]. There are also other factors that can cause machining errors such as cutting heats, clamping forces and residual stress [5,6].…”

Section: Introductionmentioning

confidence: 99%

Deflection Analysis of the Thin-Web Workpiece Structure Using Similarity Concept

Mohamad

Arifin

Ali

et al. 2011

AMR

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The thin-web structure component is widely used in aviation and aerospace industries with the reason of light weight and high performance. However, the thin-web components are tending to deflect because of their poor rigidity and the effect of cutting force during cutting process. It is required to perform of high-speed machining that can remove the large number of material in a shorter time in order to allow machining of such structure. The performance of high-speed machining operation is restricted by the static and dynamic stiffness of the tool and part that can cause some problems such as regenerative chatter and ‘push-off’. The tool path plays an important function to avoid the problem occurs as it assists to reduce the workpiece vibration during machining. The optimization of tool path is done by determining the element removal sequences and the materials removal are implemented using milling cutter. The maximum deflection for each element removed is recorded in order to define the optimum solution of element removal sequences. The analysis shows that there are significant effects of workpiece stiffness with relation to the cutting parameters setting.

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Review on Deflection Compensation Methods for Machining of Thin-Walled Components

Cited by 5 publications

References 30 publications

Study on milling flatness control method for TC4 titanium alloy thin-walled parts under ice fixation

Study on milling flatness control method for TC4 titanium alloy thin-walled parts under ice fixation

Numerical evaluation of cutting strategies for thin-walled parts

Deflection Analysis of the Thin-Web Workpiece Structure Using Similarity Concept

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