Analytical modeling of residual stress in orthogonal cutting considering tool edge radius effect

Yang, Dong; Xiao, Xiao; Liang, Xiaoliang

doi:10.1007/s00170-019-03744-9

Cited by 20 publications

(9 citation statements)

References 33 publications

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“…However, the machining time will be increased by reducing the feed rate according to Eq. (12). Moreover, increasing the spindle speed can decrease the cutting forces according to Eq.…”

Section: Fig 2 Flowchart Of the Virtual Machining Systemmentioning

confidence: 99%

“…To decrease the residual stress in machined parts using turning operations, the effects of cutting tool parameters, such as tool nose radius and tool wear on residual stresses, are investigated by Lin et al [11]. Cutting tool parameters, such as tool edge radius, are investigated by Yang et al [12] in order to decrease the residual stress in machined parts. To study the effects of cutting-edge radius and cutting forces on residual stresses of machined parts, a finite element model is developed by Nasr et al [13].…”

Section: Introductionmentioning

confidence: 99%

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Virtual Minimization of Residual Stress and Deflection Error in the Five-Axis Milling of Turbine Blades

Soori

Asmael

2021

SV-JME

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To simulate and analyse the real machined parts in virtual environments, virtual machining systems are applied to the production processes. Due to friction, chip forming, and the heat produced in the cutting zone, parts produced using machining operation have residual stress effects. The machining force and machining temperature can cause the deflection error in the machined turbine blades, which should be minimized to increase the accuracy of machined blades. To minimize the residual stress and deflection error of machined parts, optimized machining parameters can be obtained. In the present research work, the application of a virtual machining system is presented to predict and minimize the residual stress and deflection error in a five-axis milling operations of turbine blades. In order to predict the residual stress and deflection error in machined turbine blades, finite element analysis is implemented. Moreover, to minimize the residual stress and deflection error in machined turbine blades, optimized parameters of machining operations are obtained by using a genetic algorithm. To validate the research work, experimentally determining residual stress by using a X-ray diffraction method from the machined turbine blades is compared with the finite element results obtained from the virtual machining system. Also, in order to obtain the deflection error, the machined blades are measured by using the CMM machines. Thus, the accuracy and reliability of machined turbine blades can be increased by analysing and minimizing the residual stress and deflection error in virtual environments.

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“…However, the machining time will be increased by reducing the feed rate according to Eq. (12). Moreover, increasing the spindle speed can decrease the cutting forces according to Eq.…”

Section: Fig 2 Flowchart Of the Virtual Machining Systemmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Virtual Minimization of Residual Stress and Deflection Error in the Five-Axis Milling of Turbine Blades

Soori

Asmael

2021

SV-JME

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show abstract

“…These analytical models have been generated for various machining conditions and platforms, including the prediction of MIRS in turning and milling machining operations. In the turning process, analytical models have been developed for orthogonal cutting of various materials by looking at the mechanical stresses and the thermal loads involved [4,5], whereas other pieces of research have also included the influence of the thermal stresses [6]. Similarly, in the milling process, analytical models have been developed for both orthogonal [7,8] and oblique cutting [9][10][11][12].…”

Section: Mirs Controlmentioning

confidence: 99%

Machining Digital Twin using real-time model-based simulations and lookahead function for closed loop machining control

Ward

Sun

Dominguez-Caballero

et al. 2021

Int J Adv Manuf Technol

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The future of machining lies in the fully autonomous machine tool. New technologies must be developed that predict, sense and action intelligent decisions autonomously. Digital twins are one component on this journey and are already having significant impact in the manufacturing industries. Despite this, the implementation of machining Digital Twins has been slow due to the computational burden of simulating cutting forces online resulting in no commercially available Digital Twin that can automatically control the machining process in real time. Addressing this problem, this research presents a machining Digital Twin capable of real-time adaptive control of intelligent machining operations. The computational bottleneck of calculating cutter workpiece engagements online has been overcome using a novel method which combines a priori calculation with real-time tool centre point position data. For the first time, a novel online machine-induced residual stress control system is presented which integrates real-time model-based simulations with online feedback for closed loop residual stress control. Autonomous Digital Twin technologies presented also include chatter prediction and control and adaptive feed rate control. The proposed machining Digital Twin system has been implemented on a large-scale CNC machine tool designed for high-speed machining of aerostructure parts. Validation case studies have been conducted and are presented for each of the machining Digital Twin applications.

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“…Selecting the rake angle of the tool as 0 • can reduce the influence of the tool shape on the shape precision of the forming method. In fine machining, the tool edge radius has a great influence on the machining quality [26]. Studies by Wu et al [27] showed that the height of the burr increases as the tool edge radius increases.…”

Section: Equipment and Cutting Toolsmentioning

confidence: 99%

Precision Cutting of the Molds of an Optical Functional Texture Film with a Triangular Pyramid Texture

Huang

et al. 2020

Micromachines

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Based on an analysis of the precision and preparation technology of an optical texture film with a triangular pyramid texture, the technical requirements of the original mold were determined, and precision shaping planning technology was adopted to process the original mold. The shape error of the optical texture mold of the triangular pyramid was assessed by defining the area ratio of the retro-reflection. The influence of the tool nose radius and exit burr on the area ratio of the retro-reflection were analyzed. By optimizing the cutting tools, cutting materials and cutting boundaries, a five-axis ultra-precision machining system was used to plan the triangular pyramid structure with a base length of 115 µm and an included angle between two sides of 70.5°. The experimental results indicate that the dimension error of the triangular pyramid element is less than 1 µm, the angle error of the included angle between two sides is less than 0.05°, and the average roughness of the side of the triangular pyramid can reach 9.2 nm, which satisfies the processing quality requirements of the triangular pyramid texture mold.

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Analytical modeling of residual stress in orthogonal cutting considering tool edge radius effect

Cited by 20 publications

References 33 publications

Virtual Minimization of Residual Stress and Deflection Error in the Five-Axis Milling of Turbine Blades

Virtual Minimization of Residual Stress and Deflection Error in the Five-Axis Milling of Turbine Blades

Machining Digital Twin using real-time model-based simulations and lookahead function for closed loop machining control

Precision Cutting of the Molds of an Optical Functional Texture Film with a Triangular Pyramid Texture

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