Abstract
An enhanced simulation model is presented in this paper to predict form deviations in end milling processes of thin-walled structures. The calculation of tool engagement is based on level curves representing surface geometry of the workpiece and the NC code driven sweep volume. To consider influences of force-induced deflections resulting in static form errors on machined surface of the workpiece, a model for superposed stresses is enclosed. Derived from the tool engagement, the cutting force is predicted using a parametric force model. The experimental investigations within the measuring of static and dynamic form errors during processing and afterwards are shown and measurement results are compared with results of the cutting simulation to verify the proposed method. The presented achievements are deduced from research activities aiming at an increased understanding of shape deviation induced by interactions between tool, workpiece and clamping device during machining.
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Acknowledgement
The CRC653/K2 is funded by the Deutsche Forschungsgemeinschaft (DFG). The Institute of Production Engineering and Machine Tools (IFW) is partner of the EU-funded FP6 Innovative Production Machines and Systems (I*PROMS) Network of Excellence (http://www.iproms.org). The authors would like to express their thanks to the anonymous reviewers, whose constructive suggestions have improved the quality of this paper. We thank Ms. Christine Yang and Ms. Rachelle Barr also for their kind help.
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Denkena, B., Schmidt, C. Experimental investigation and simulation of machining thin-walled workpieces. Prod. Eng. Res. Devel. 1, 343–350 (2007). https://doi.org/10.1007/s11740-007-0017-9
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DOI: https://doi.org/10.1007/s11740-007-0017-9