FEM-Based Simulation for Workpiece Deformation in Thin-Wall Milling

Jun Wang; Soichi Ibaraki; Atsushi Matsubara; Kosuke Shida; Takayuki Yamada

doi:10.20965/ijat.2015.p0122

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IJAT Vol.9 No.2 pp. 122-128

doi: 10.20965/ijat.2015.p0122

(2015)

Paper:

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FEM-Based Simulation for Workpiece Deformation in Thin-Wall Milling

Jun Wang, Soichi Ibaraki, Atsushi Matsubara, Kosuke Shida, and Takayuki Yamada

Department of Microengineering, Kyoto University
C1N06, Bld. C3, Katsura Campus, Nishikyo-ku, Kyoto 606-8540, Japan

Received:

November 8, 2014

Accepted:

January 28, 2015

Published:

March 5, 2015

Keywords:

deformation, thin wall, milling, rib

Abstract

This paper focuses on the deformation of a thin wall during the milling process. Cutting experiments were performed to investigate the influence of the workpiece thickness on its deformation and the cutting force. An FEM-based model was developed to simulate the deformation of a thin-wall workpiece during the milling process. With a tool’s rotation, the cutting force is distributed along the helical cutting edge, and the workpiece deformation can be calculated for a given time interval. The simulated results were compared with those of a simpler model where a constant cutting force is uniformly distributed along an oblique line representing the material removal by a cylindrical tool. Finally, the application of these results to the design of ribs for thin-wall parts during machining was considered.

Cite this article as:

J. Wang, S. Ibaraki, A. Matsubara, K. Shida, and T. Yamada, “FEM-Based Simulation for Workpiece Deformation in Thin-Wall Milling,” Int. J. Automation Technol., Vol.9 No.2, pp. 122-128, 2015.

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References

[1] E. Budak and Y. Altintas, “Modeling and avoidance of static form errors in peripheral milling of plates,” Int. J. of Machine Tools and Manufacture, Vol.35, Issue 3, pp. 459-476, 1995.
[2] A. Matsubara and S. Ibaraki, “Monitoring and control of cutting forces in machining processes: a review,” Int. J. of Automation Technology (IJAT), Vol.3, No.4, pp. 445-456, 2009.
[3] T. Matsumura, T. Shirakashi, and E. Usui, “Adaptive Cutting Force Prediction in Milling Processes,” Int. J. of Automation Technology (IJAT), Vol.4, No.3, pp. 221-228, 2010.
[4] T. Matsumura, et al., “Predictive Cutting Force Model and Cutting Force Chart for Milling with Cutter Axis Inclination,” Int. J. of Automation Technology (IJAT), Vol.7, No.1, pp. 30-38, 2013.
[5] J. Kaneko and K. Horio, “Fast Cutter Workpiece Engagement Estimation Method for Prediction Of Instantaneous Cutting Force in Continuous Multi-Axis Controlled Machining,” Procedia CIRP 4, 151-156, 2012.
[6] H. Ning, W. Zhigang, and J. Chengyu, et al., “Finite element method analysis and control stratagem for machining deformation of thin-walled components,” J. of materials processing technology, Vol.139, Issue 1, pp. 332-336, 2003.
[7] J.-S. Tsai and C.-L. Liao, “Finite-element modeling of static surface errors in the peripheral milling of thin-walled workpieces,” J. of Materials Processing Technology, Vol.94, Issue 2, pp. 235-246, 1999.
[8] M. Wan, et al., “Strategies for error prediction and error control in peripheral milling of thin-walled workpiece,” Int. J. of Machine Tools and Manufacture, Vol.48, Issue 12, pp. 1366-1374, 2008.
[9] Y. Huang and J. H. Oliver, “Integrated simulation, error assessment, and tool path correction for five-axis NC milling,” J. of Manufacturing Systems, Vol.14, Issue 5, pp. 331-344, 1995.
[10] S. Ratchev, et al., “An advanced FEA based force induced error compensation strategy in milling,” Int. J. of Machine Tools and Manufacture, Vol.46, Issue 5, pp. 542-551, 2006.
[11] S. Smith and D. Dvorak, “Tool path strategies for high speed milling aluminum workpieces with thin webs,” Mechatronics, Vol.8, Issue 4, pp. 291-300, 1998.
[12] Y. Koike, et al., “Cutting path design to minimize workpiece displacement at cutting point: Milling of thin-walled parts,” Int. J. of Automation Technology (IJAT), Vol.6, No.5 pp. 638-647, 2012.
[13] K. Iwabe, H. Matsuhashi, and H. Akutsu, et al., “High-Accuracy Machining of Thin-Walled Workpiece by Non-rotational Tool-Analysis of Machining Accuracy Based on Deflection of Tool and Workpiece Using FEM,” Int. J. of Automation Technology (IJAT), Vol.4, No.3, 2010.
[14] Y. Altintas, A. Spence, and J. Tlusty, “End milling force algorithms for CAD systems,” CIRP Annals-Manufacturing Technology, Vol.40, Issue 1, pp. 31-34, 1991.

This article is published under a Creative Commons Attribution-NoDerivatives 4.0 Internationa License.

[1] [1] E. Budak and Y. Altintas, “Modeling and avoidance of static form errors in peripheral milling of plates,” Int. J. of Machine Tools and Manufacture, Vol.35, Issue 3, pp. 459-476, 1995.

[2] [2] A. Matsubara and S. Ibaraki, “Monitoring and control of cutting forces in machining processes: a review,” Int. J. of Automation Technology (IJAT), Vol.3, No.4, pp. 445-456, 2009.

[3] [3] T. Matsumura, T. Shirakashi, and E. Usui, “Adaptive Cutting Force Prediction in Milling Processes,” Int. J. of Automation Technology (IJAT), Vol.4, No.3, pp. 221-228, 2010.

[4] [4] T. Matsumura, et al., “Predictive Cutting Force Model and Cutting Force Chart for Milling with Cutter Axis Inclination,” Int. J. of Automation Technology (IJAT), Vol.7, No.1, pp. 30-38, 2013.

[5] [5] J. Kaneko and K. Horio, “Fast Cutter Workpiece Engagement Estimation Method for Prediction Of Instantaneous Cutting Force in Continuous Multi-Axis Controlled Machining,” Procedia CIRP 4, 151-156, 2012.

[6] [6] H. Ning, W. Zhigang, and J. Chengyu, et al., “Finite element method analysis and control stratagem for machining deformation of thin-walled components,” J. of materials processing technology, Vol.139, Issue 1, pp. 332-336, 2003.

[7] [7] J.-S. Tsai and C.-L. Liao, “Finite-element modeling of static surface errors in the peripheral milling of thin-walled workpieces,” J. of Materials Processing Technology, Vol.94, Issue 2, pp. 235-246, 1999.

[8] [8] M. Wan, et al., “Strategies for error prediction and error control in peripheral milling of thin-walled workpiece,” Int. J. of Machine Tools and Manufacture, Vol.48, Issue 12, pp. 1366-1374, 2008.

[9] [9] Y. Huang and J. H. Oliver, “Integrated simulation, error assessment, and tool path correction for five-axis NC milling,” J. of Manufacturing Systems, Vol.14, Issue 5, pp. 331-344, 1995.

[10] [10] S. Ratchev, et al., “An advanced FEA based force induced error compensation strategy in milling,” Int. J. of Machine Tools and Manufacture, Vol.46, Issue 5, pp. 542-551, 2006.

[11] [11] S. Smith and D. Dvorak, “Tool path strategies for high speed milling aluminum workpieces with thin webs,” Mechatronics, Vol.8, Issue 4, pp. 291-300, 1998.

[12] [12] Y. Koike, et al., “Cutting path design to minimize workpiece displacement at cutting point: Milling of thin-walled parts,” Int. J. of Automation Technology (IJAT), Vol.6, No.5 pp. 638-647, 2012.

[13] [13] K. Iwabe, H. Matsuhashi, and H. Akutsu, et al., “High-Accuracy Machining of Thin-Walled Workpiece by Non-rotational Tool-Analysis of Machining Accuracy Based on Deflection of Tool and Workpiece Using FEM,” Int. J. of Automation Technology (IJAT), Vol.4, No.3, 2010.

[14] [14] Y. Altintas, A. Spence, and J. Tlusty, “End milling force algorithms for CAD systems,” CIRP Annals-Manufacturing Technology, Vol.40, Issue 1, pp. 31-34, 1991.