Distortion in milling of structural parts

Hashemi, Arash; Lazoğlu, İsmail

doi:10.1016/j.cirp.2019.04.053

Cited by 29 publications

(11 citation statements)

References 11 publications

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“…When analyzing the bending distortion of a long beam, the beam is fixed for one section and the other end is hinged. Furthermore, the part can be simplified into a simply supported beam, and the maximum deflection value of the bending distortion is used to characterize the distortion [5,19,20]. Based on the calculation formula of bending distortion in the literature [2], the predicted bending distortion of the final part (PV final ) can be calculated as follows.…”

Section: The Part Geometrymentioning

confidence: 99%

Machining Distortion Minimization of Monolithic Aircraft Parts Based on the Energy Principle

Fan

Tian

et al. 2020

Metals

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Machining distortion is a recurring problem in the machining of monolithic aircraft parts. This paper aims to study the machining distortion minimization of monolithic aircraft parts. Firstly, the energy principle of machining distortion was analyzed. Then, a rapid prediction model of the final part distortion for beam parts was proposed based on the equivalent stress, and the initial bending strain energy contained in the final part was used to characterize the bending distortion risk of the final part. Numerical simulation and milling experiments verified the effectiveness of the proposed prediction model. The relative error between the experimental and calculated results does not exceed 26.5%. Finally, the influence of initial residual stress fluctuation, part geometry and the part location on part distortion was analyzed from the energy point of view. The obtained results indicated that the expected final part distortion can be minimized by adjusting these three factors.

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Section: The Part Geometrymentioning

confidence: 99%

Machining Distortion Minimization of Monolithic Aircraft Parts Based on the Energy Principle

Fan

Tian

et al. 2020

Metals

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“…In the case of face milling with an entering angle of 90° ( Figure 1 a), the direction of the cutting force is radial [ 8 , 9 ]. The stiffness of the tool in the radial direction is low, which entails the necessity of reducing milling efficiency and may pose an increased risk of an occurrence of machining vibrations [ 10 , 11 ].…”

Section: Introductionmentioning

confidence: 99%

High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude

et al. 2021

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High feed Milling is a new milling method, which allows to apply high feed rates and increase machining efficiency. The method utilizes face cutters with a very small entering angle, of about 10°–20°. Thus, the cut layer cross-section is different than in traditional milling. In order to examine the high feed milling (HFM), experimental tests were conducted, preceded by an analysis of cutting zones when milling with an HF face cutter. The face milling tests of 42CrMo4 steel with the use of an HF cutter characterized by an entering angle, dependent on axial depth of cut ap and insert radius r values, as well as with a conventional face cutter with the entering angle of 45° were performed. The study focused on analyzing the vibration amplitude, cutting force components in the workpiece coordinate system, and surface roughness. The experimental tests proved, that when milling with constant cut layer thickness, the high feed cutter allowed to obtain twice the cutting volume in comparison with the conventional face cutter. However, higher machining efficiency resulted in an increase in cutting force components. Furthermore, the results indicate significantly higher surface roughness and higher vibration amplitudes when milling with the HF cutter.

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“…A number of studies focus on predicting the behavior of thin-walled workpieces during cutting through finite element studies or on the basis of general mathematical models or those developed specifically for a given application [ 5 , 6 ].…”

Section: Introductionmentioning

confidence: 99%

“…The authors of the study [ 6 ] focused on predicting thermal loads and deformations of a thin-walled workpiece made of aluminum alloy used in the aviation industry. Laser sensors at two measuring points were used to measure the deformation.…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Displacement of Thin-Walled Workpiece Using a High-Speed Camera during Peripheral Milling of Aluminum Alloys

2021

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The paper presents the possibilities of a high-speed camera in recording displacements of thin-walled workpiece during milling made of aluminum alloys, which allowed for an analysis in which it was compared to other methods of testing the deflection of such elements. The tests were carried out during peripheral milling with constant cutting parameters. Deflection of thin-walled workpiece due to cutting forces was measured using a high-speed camera and a laser displacement sensor. Additionally, the experimental results were compared with the theoretical results obtained with the use of the finite element method. The research proved the effectiveness of the use of high-speed camera in diagnostics of thin-walled workpieces during milling with an accuracy of up to 11% compared to measurements made with a displacement laser sensor.

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Distortion in milling of structural parts

Cited by 29 publications

References 11 publications

Machining Distortion Minimization of Monolithic Aircraft Parts Based on the Energy Principle

Machining Distortion Minimization of Monolithic Aircraft Parts Based on the Energy Principle

High-Performance Face Milling of 42CrMo4 Steel: Influence of Entering Angle on the Measured Surface Roughness, Cutting Force and Vibration Amplitude

Analysis of the Displacement of Thin-Walled Workpiece Using a High-Speed Camera during Peripheral Milling of Aluminum Alloys

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