2.50
Hdl Handle:
http://hdl.handle.net/10547/276015
Title:
Milling error prediction and compensation in machining of low-rigidity parts
Authors:
Ratchev, Svetan; Liu, Shulong; Huang, Wei; Becker, Adib A.
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.
Affiliation:
School of the Mechanical, Material, Engineering Manufacturing and Management, University of Nottingham
Citation:
Ratchev, S., Liu, S., Huang, W. and Becker, A.A., (2004) 'Milling error prediction and compensation in machining of low-rigidity parts' International Journal of Machine Tools and Manufacture 44 (15):1629-1641
Publisher:
Elsevier
Journal:
International Journal of Machine Tools and Manufacture
Issue Date:
2004
URI:
http://hdl.handle.net/10547/276015
DOI:
10.1016/j.ijmachtools.2004.06.001
Additional Links:
http://linkinghub.elsevier.com/retrieve/pii/S0890695504001439
Type:
Article
Language:
en
ISSN:
0890-6955
Appears in Collections:
Centre for Research in Distributed Technologies (CREDIT)

Full metadata record

DC FieldValue Language
dc.contributor.authorRatchev, Svetanen_GB
dc.contributor.authorLiu, Shulongen_GB
dc.contributor.authorHuang, Weien_GB
dc.contributor.authorBecker, Adib A.en_GB
dc.date.accessioned2013-03-26T12:47:56Z-
dc.date.available2013-03-26T12:47:56Z-
dc.date.issued2004-
dc.identifier.citationRatchev, S., Liu, S., Huang, W. and Becker, A.A., (2004) 'Milling error prediction and compensation in machining of low-rigidity parts' International Journal of Machine Tools and Manufacture 44 (15):1629-1641en_GB
dc.identifier.issn0890-6955-
dc.identifier.doi10.1016/j.ijmachtools.2004.06.001-
dc.identifier.urihttp://hdl.handle.net/10547/276015-
dc.description.abstractThe 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.en_GB
dc.language.isoenen
dc.publisherElsevieren_GB
dc.relation.urlhttp://linkinghub.elsevier.com/retrieve/pii/S0890695504001439en_GB
dc.rightsArchived with thanks to International Journal of Machine Tools and Manufactureen_GB
dc.subjectmilling forceen_GB
dc.subjectdeflection predictionen_GB
dc.subjecterror compensationen_GB
dc.titleMilling error prediction and compensation in machining of low-rigidity partsen
dc.typeArticleen
dc.contributor.departmentSchool of the Mechanical, Material, Engineering Manufacturing and Management, University of Nottinghamen_GB
dc.identifier.journalInternational Journal of Machine Tools and Manufactureen_GB
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