In this paper a technique to compute the 3-axis toolpath for a thin-wall component is presented aiming at maximizing the engagement conditions, keeping the geometry in tolerance. The toolpath generation is based on the static deflection of the component, predicted by coupling a mechanistic model of the cutting forces with a FE model of the workpiece, including, at each machining step, material removal mechanism. The algorithm follows the milling cycle in the reverse order: starts from the finished part, computes the maximum allowable radial depth of cut, and, adding material accordingly, generates the toolpath until the stock is built. The proposed technique has been experimentally validated, proving its effectiveness.
The turning of thin-walled components is a challenging process due to the flexibility of the parts. On one hand, static deflection due to the cutting forces causes geometrical and dimensional errors, while unstable vibration (i.e., chatter) could compromise surface quality. In this work, a method for fixturing optimization for thin-walled components in turning is proposed. Starting from workpiece geometry and toolpath, workpiece deflections and system dynamics are predicted by means of an efficient finite element modeling approach. By analyzing the different clamping configurations, a method to find the most effective solution to guarantee the required tolerances and stable cutting conditions is developed. The proposed method was tested as a case study, showing its application and achievable results.
Unstable vibrations (i.e., chatter) onset is one of the main limits to productivity in deep boring bar processes. Active damping systems allow to increase machining stability in different configurations (i.e., tool setup), without requiring cutting system dynamic characterization. Design of an active boring bar involves the development of monitoring system (sensors), actuation system and control logic. While several control logics were evaluated and discussed, few design solutions were presented in the literature, focusing only on building prototypes to demonstrate control logic effectiveness. In the presented work, a deep analysis of the main issues and requirements related to active boring design was carried out and a systematic approach to tackle all the critical aspects was developed. The results of the proposed method are: (i) optimal actuators positioning able to damp vibration along two directions; (ii) preload system design guaranteeing the correct actuator preloading for the operating conditions; (iii) covers design to protect actuators and ensure the dynamic and static equivalence between active and standard boring bar. Following this approach, an active boring bar was designed, realized and tested. The results prove the required equivalence between active and original boring bar and assess the damping effect.
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