Abstract:Geometrical inaccuracies, in a statically clampedworkpiece subjected to cutting forces,aremainly caused by the contact deformationsat the locators and the structural deformations in the body of the workpiece.In addition, during machining the structural deformations continuously increase as the workpiece keeps losing its stiffness on account of metal removal. This condition is also encountered while machining thin walled workpieces. To investigate the relative significance of the structural and the contact deformations,fixture elements workpieceand the contact at their interface is modelled numerically in ANSYS 17.2.A milling fixture with 3-2-1 location principle and two hydraulically operated clamps is developed for pocket milling operation on Al-6061-T6 and a number of experiments are conducted to obtain structural deformation of workpiece. The numerical simulations and experiments were performed for different percentages of metal removal (0%, 20% and 50%) under various clamping pressures varying from 15-25 bar (kg/cm 2 ).The numerically predicted deformations show a good agreement with experimental results. The studies would help in developing an adaptive clamping mechanism to compensate for the changing structural stiffness of the workpiece and thereby keeping a check on the deformations, and hence the machining accuracies.
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