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

  • Wei Huang
    ,
  • Svetan Ratchev
    ,
  • Shulong Liu
    ,
  • Adib A. Becker
Research Output: Contribution to journal Article Peer-review

Abstract

The paper reports on a new integrated methodology for modelling and prediction of surface errors caused by deflection during machining of low-rigidity components. The proposed approach is based on identifying and modelling key processing characteristics that influence part deflection, predicting the workpiece deflection through an adaptive flexible theoretical force-FEA deflection model and providing an input for downstream decision making on error compensation. A new analytical flexible force model suitable for static machining error prediction of low-rigidity components is proposed. The model is based on an extended perfect plastic layer model integrated with a FE model for prediction of part deflection. At each computational step, the flexible force is calculated by taking into account the changes of the immersion angles of the engaged teeth. The material removal process at any infinitesimal segment of the milling cutter teeth is considered as oblique cutting, for which the cutting force is calculated using an orthogonal–oblique transformation. This study aims to increase the understanding of the causes of poor geometric accuracy by considering the impact of the machining forces on the deflection of thin-wall structures. The reported work is a part of an ongoing research for developing an adaptive machining planning environment for surface error modelling and prediction and selection of process and tool path parameters for rapid machining of complex low-rigidity high-accuracy parts.

Publication Information

Output type

Research Output: Contribution to journal Article Peer-review

Original language

English

Pages from-to (Number of pages)

Pages 1629-1641

Journal (Volume, Issue Number)

International Journal of Machine Tools and Manufacture (Volume 44, Issue 15)

Publication milestones

  • Published - 01/01/2004

Publication status

Published - 01/01/2004

ISSN

0890-6955

External Publication IDs

  • handle.net: 10547/276015
  • Scopus: 6344270103

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