Accuracy analysis of tool deflection error modelling in prediction of milled surfaces by a virtual machining system

Soori, Mohsen; Arezoo, Behrooz; Habibi, Mohsen

doi:10.1504/ijcat.2017.086015

Cited by 47 publications

(23 citation statements)

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“…An advanced analysis system is provided by virtual environments so to analyze and modify the manufacturing operations. Milling machining operations as a common method of part production are analyzed and modified in virtual environments by Soori et al [7,8,9,10]. Moreover, the FSW operation can be analyzed so to be modified in virtual environments.…”

Section: T He New Methods Of Welding Operation Is Presented Bymentioning

confidence: 99%

Recent Development in Friction Stir Welding Process: A Review

Soori¹,

Asmael²,

Solyalı³

2020

SAE Int. J. Mater. Manf.

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The Friction stir welding (FSW) is recently presented so to join different materials without the melting process as a solid-state joining technique. A widely application for the FSW process is recently developed in automotive industries. To create the welded components by using the FSW, the plunged probe and shoulder as welding tools are used. The Finite Element Method (FEM) can be used so to simulate and analyze material flow during the FSW process. As a result, thermal and mechanical stresses on the workpiece and welding tool can be analyzed and decreased. Effects of the welding process parameters such as tool rotational speed, welding speed, tool tilt angle, depth of the welding tool, and tool shoulder diameter can be analyzed and optimized so to increase the efficiency of the production process. Material characteristics of welded parts such as hardness or grain size can be analyzed so to increase the quality of part production. Residual stress, strain, deformation, and estimations of the temperatures in the welding area can be predicted using the simulation of FSW in the FEM software. Heat generation, thermal, and thermomechanical analyses can also be implemented on the welded parts to analyze the distribution of temperature and strain in the heat-affected zone (HAZ). Moreover, welding operations of dissimilar metals can be analyzed using numerical simulation to increase the capabilities of the welding methodology in different industrial applications. In this article, a review of the FSW process is presented. As a result, the research filed can be moved forward by reviewing and analyzing recent achievements in the published papers. This article is part of a Special Issue on Lightweighting Materials for Automotive Applications.

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Section: T He New Methods Of Welding Operation Is Presented Bymentioning

confidence: 99%

Recent Development in Friction Stir Welding Process: A Review

Soori¹,

Asmael²,

Solyalı³

2020

SAE Int. J. Mater. Manf.

Self Cite

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“…Structural efficiency of a wind turbine blade is studied by Buckney et al [17] in order to improve designing process, minimizing weight and reducing the cost of wind energy. To analyze and modify the machining operations in virtual environments, virtual machining systems and applications is presented by Soori et al [18][19][20][21]. Virtual machining system and application is also presented by Altintas and Merdol [22] in order to obtain optimized condition of milling operations.…”

Section: -Review Of Research Work In the Deflection Errors Of Thin mentioning

confidence: 99%

“…(8) and cutting tool life according to the Eq. (18). It is clear that the presented mathematical models of the cutting forces, cutting temperature, time of machining operations, surface roughness, feed rate and cutting tool life are related together which should be considered as an optimization problem.…”

Section: = (17)mentioning

confidence: 99%

Deflection Error Prediction and Minimization in 5-Axis Milling Operations of Thin-Walled Impeller Blades

Soori

Asmael

2020

Preprint

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To enhance accuracy as well as efficiency in process of machining operations, the virtual machining systems are developed. Free from surfaces of sophisticated parts such as turbine blades, airfoils, impellers, and aircraft components are produced by using the 5-axis CNC machine tools which can be analyzed and developed by using virtual machining systems. The machining operations of thin walled structures such as impeller blades are with deflection errors due to cutting forces and cutting temperatures. The flexibility of thin walled impeller blades can cause machining defects such as overcut or undercut. So, the desired accuracy in the machined impeller blades can be achieved by decreasing the deflection error in the machining operations. To minimize the deflection of machined impeller blades, optimized machining parameters can be obtained. An application of virtual machining system in predicting and minimizing the deflection errors of 5-Axis CNC machining operations of impeller blades is presented in the study to increase accuracy and efficiency in process of part production. The finite element analysis is applied to obtain the deflection error in machined impeller blades. In order to minimize the deflection error of impeller blades in the machining operations, the optimization methodology based on the Genetic algorithm is applied. The impeller is machined by using the 5-axis CNC machine tool in order to validate the developed virtual machining system in the study. Then, the machined impeller is measured by using the CMM machines to obtain the deflection error. As a result, the deflection error of in machining operations of impeller by using 5-Axis CNC machine tools can be decreased in order to enhance accuracy and efficiency of part manufacturing.

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“…Although the flow resistance is of complex form, of complex, but from the sense flow energy distribution, the flow resistance is proportional to the square of flow velocity and the water surface gradient, so the indicator of a ship's rapidsascending ability can be constructed by the flow energy parameter, which is shown as follows: (Soori et al, 2017)…”

Section: Determination Of Calculation Parameters For Typical Ships Inmentioning

confidence: 99%

Modelling and simulation of the ship rapids-ascending ability in Lancang River

Zhizhou

Tong

Feng

et al. 2019

IJCAT

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Ship sailing resistance is an important indicator to judge the navigation capacity of a waterway. In this paper the empirical formula of Zwaan Kopf is modified according to the ship model test results in Lancang River channel, tests reveal that the navigation capacity of the channel can be represented by a critical composite flow energy indicator E = 1.20. In order to validate the reliability of experimental results, this paper established a two-dimensional numerical model to simulate the water flow and ship sailing process in the channel. The relationship of flow energy indicator and the sailing velocity is studied by simulating a typical 500t ship sailing in the channel of Lancang River, and the results show that the value of critical flow energy indicator E in the channel of Lancang River by simulation fits well with the tests, so the simulation method proposed in this paper is reasonable and feasible, and the critical flow energy indicator simulated by this method has important reference value in engineering.

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Accuracy analysis of tool deflection error modelling in prediction of milled surfaces by a virtual machining system

Cited by 47 publications

References 0 publications

Recent Development in Friction Stir Welding Process: A Review

Recent Development in Friction Stir Welding Process: A Review

Deflection Error Prediction and Minimization in 5-Axis Milling Operations of Thin-Walled Impeller Blades

Modelling and simulation of the ship rapids-ascending ability in Lancang River

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