The application of tool deflection knowledge in process planning to meet geometric tolerances

Ong, T.S.; Hinds, B. K.

doi:10.1016/s0890-6955(03)00027-0

Cited by 26 publications

(11 citation statements)

References 13 publications

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“…Application of tool deflection knowledge in process planning is presented by Ong and Hinds (2003) to meet desired geometric tolerances by selecting optimal feed rates. Tool deflection error compensation in peripheral milling of curved geometries is presented by Rao and Rao (2006) in order to increase accuracy in machining of curved geometries.…”

Section: Review Of the Research Workmentioning

confidence: 99%

Accuracy analysis of tool deflection error modelling in prediction of milled surfaces by a virtual machining system

Soori

Arezoo

Habibi

2017

IJCAT

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Accuracy of produced parts in machining process is influenced by many errors such as tool deflection as well as geometrical deviations of machine tool structure. To increase accuracy and productivity in part manufacturing, the errors are modelled by using mathematical concepts. This paper presents an application for the virtual machining systems to analyse accuracy in modelling of tool deflection error. A virtual machining system is used to create actual parts in virtual environments. Then, a comparison for different methods of tool deflection error such as cantilever beam model of the cutting tool, Finite Element Method (FEM) of the cutting tool and workpiece and geometrical model of the cutting tool effects on the workpiece is presented to show accuracy and reliability of the methods in prediction of milled surfaces. So, capabilities and difficulties of the methods in the error modelling are presented to increase accuracy and efficiency in part manufacturing.

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Section: Review Of the Research Workmentioning

confidence: 99%

Accuracy analysis of tool deflection error modelling in prediction of milled surfaces by a virtual machining system

Soori

Arezoo

Habibi

2017

IJCAT

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“…The cutter is usually simplified as cantilever beam [14][15][16][17][18][19], and each cross section along the axial direction is assumed as the same. In fact the error between each cross section exists because of an angle of Δ , which is depicted in Fig.…”

Section: Cutter Stiffnessmentioning

confidence: 99%

Nonlinear dynamic characteristic of the spindle-cutter system

Gao¹,

Zhang²,

Wang³

2016

J. vibroeng.

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A nonlinear dynamic model of spindle-cutter coupling system under cutting force, which takes into account the cutter stiffness and the nonlinearity of bearing clearance, is established. Analysis of the cross-section of a two-flute end mill is conducted to determine cutter stiffness. Then, the calculated cutter stiffness is introduced into the nonlinear dynamic model of coupling system. In the modeling of cutting force, the cutting width takes into account the cutter tip displacement. Moreover, nonlinear dynamic characteristics of spindle-cutter coupling system are studied and the effects of bearing clearance on the response of cutter tip are discussed as well, considering unbalanced force. The numerical results show that the bearing clearance strongly affects the equilibrium position. With different values of bearing clearance and rotation speed, the responses of cutter tip exhibit periodic, quasi-periodic and chaotic characteristics. Dynamic characteristics of spindle-cutter system depends on the bearing clearance and rotation speed. The proper bearing clearance and rotation speed should be chosen to ensure a stable cutting and high cutting rate according to the bifurcation diagram. The response of the cutter tip is a quasi-periodic motion when the cutting force is considered. The time-domain response of cutter tip predicted by nonlinear dynamic analysis can provide the basis for machining error prediction.

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“…Cutting force model is the fundamental element in milling process simulation as it helps inanalyzing the process without conducting rigorous experimentation. A series of force models are reported in the literature which can be grouped into three categories; Experimental models [1,2], Mechanics based analytical force models [3,4] and Mechanistic force models [5,6,7 8]. The present study uses Mechanistic force model due to its ease of implementation and integration with other elements involved in predicting surface error [5].Mechanistic force model simulates milling process into discrete increments; angle by angle, flute by flute and by dividing an end mill into axial segments slice by slice.…”

Section: Introductionmentioning

confidence: 99%

Modeling of Static Surface Error in End-Milling of Thin-Walled Geometries

Desai¹,

Arora²,

Agarwal³

2019

IJPTECH

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In recent years, machining replaced metal working and assembly operations as a process to fabricate thin-walled components in the monolithic form. End Milling is preferred machining operation for such components due to its versatility to generate complex shapes in a variety of materials with high quality and productivity. End Milling is an intermittent cutting process with periodically varying cutting forces that causes deflection of thin-walled components owing to lower rigidity. The inherently low stiffness of thin-walled components introduces machining challenges related to static deflections of components. These deflections will result into significant amount of surface error and violation of machining tolerances. Therefore, prediction and control of surface error is an important task for process planners in achieving dimensional accuracy. This paper presents Finite Element Analysis (FEA) based methodology to predict static deflections of thin-walled components during end milling operation. The FEA model inputs cutting force values from two different variants of Mechanistic model existing in the literature and predicts static deflections. The values of deflections estimated from FEA model are transformed further into error profile using surface generation mechanism. An existing classification scheme has been modified to correlate cutting conditions and surface error profile. The results conceptualized based on surface generation mechanism are validated by performing computational experiments using commercial FEA package. The paper also investigates some of the important issues prevailing during machining of thin-walled components such as thinning and end effects.

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The application of tool deflection knowledge in process planning to meet geometric tolerances

Cited by 26 publications

References 13 publications

Accuracy analysis of tool deflection error modelling in prediction of milled surfaces by a virtual machining system

Accuracy analysis of tool deflection error modelling in prediction of milled surfaces by a virtual machining system

Nonlinear dynamic characteristic of the spindle-cutter system

Modeling of Static Surface Error in End-Milling of Thin-Walled Geometries

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