Instantaneous cutting-amount planning for machining deformation homogenization based on position-dependent rigidity of thin-walled surface parts

Ma, Jian-wei; He, Guangzhi; Liu, Zhen; Qin, Fuwen; Chen, Siyu; Zhao, Xiaoxuan

doi:10.1016/j.jmapro.2018.05.027

Cited by 41 publications

(17 citation statements)

References 33 publications

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“…The recorded signal was analyzed using wavelet decomposition, and then SVM was applied to signal whether a change on the machining condition was needed. Ma et al [111] developed a model to be implemented in adaptive control in which the feed rate was modified as a function of the real chip thickness. Feng et al [32] established a different chatter model based on wavelet analysis of the cutting forces.…”

Section: Industrial Approachmentioning

confidence: 99%

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

et al. 2019

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Thin-wall parts are common in the aeronautical sector. However, their machining presents serious challenges such as vibrations and part deflections. To deal with these challenges, different approaches have been followed in recent years. This work presents the state of the art of thin-wall light-alloy machining, analyzing the problems related to each type of thin-wall parts, exposing the causes of both instability and deformation through analytical models, summarizing the computational techniques used, and presenting the solutions proposed by different authors from an industrial point of view. Finally, some further research lines are proposed.

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Section: Industrial Approachmentioning

confidence: 99%

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

et al. 2019

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“…Recently, Rebergue et al [3] used Digital Image Correlation (DIC) in order to measure part distortion in-situ on large workpieces. The cutting force related undercut is largely studied in the field of turbine blade machining where variable stiffness and material removal rates along the tool path are problematic [4,5]. The clamping related deformations are minimised by developing intelligent fixture devices [6].The residual stress related phenomena are more challenging to separate and quantify.…”

Section: Introductionmentioning

confidence: 99%

Study of phenomena responsible for part distortions when turning thin Inconel 718 workpieces

Toubhans

Viprey

Fromentin

et al. 2021

Journal of Manufacturing Processes

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Machining thin workpieces is a challenging task as geometrical errors may result from the combination of several phenomena. Among these, elastic workpiece deformation and machining induced residual stresses may be predominant sources due to low part stiffness. There is a lack of studies trying to quantify the influence of machining induced residual stresses on the total geometrical errors. A thorough experimental methodology is developed to quantify the influence of both phenomena separately by comparing the workpiece shape and dimensions, in-situ, before and after machining, using laser sensors. The proposed methodology can also be used to quantify the geometrical errors linked to clamping or stress rebalancing following material removal. The case study is the finish turning of thin Inconel 718 workpieces using carbide tools. In the studied case, machining induced residual stresses are responsible for 3-32 % of the total geometrical errors depending on tool wear and cutting parameters.

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“…The varying stiffness due to material removal is not handled in this study as its effect is marginal in most finishing operation, where a small quantity of material is removed. The majority of studies dealing with undercut are about the milling of thin workpieces such as large thin-walled structural parts or complex shapes such as turbine blades [1]- [5]. Several research works are available to predict and compensate the undercut error.…”

Section: Introductionmentioning

confidence: 99%

“…Most of them are offline methodologies and rely on the coupling of a workpiece stiffness model and a cutting force model. An iterative algorithm based on a convergence loop at successive tool positions is often used to either model the workpiece deflection or to generate a compensated tool path prior to machining [1,3,[6][7][8].…”

Section: Introductionmentioning

confidence: 99%

A versatile approach, considering tool wear, to simulate undercut error when turning thin-walled workpieces

Toubhans

Lorong

Viprey

et al. 2021

Int J Adv Manuf Technol

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In-process workpiece elastic deflection is the major source of geometrical error when machining low-stiffness workpieces. It creates an undercut error which needs to be corrected by time-consuming and labour-intensive operations. For this reason, cutting process simulation is growing in interest. To do so, a model representing the workpiece flexibility is coupled with a model to predict the applied cutting forces. For a given tool-material set, these cutting forces depend on the cut section, which therefore depends on current deflection of the part during machining, but also on the level of tool wear. This research work focuses on developing a general coupling approach to tackle this challenge. The case study is the finish turning on thin Inconel 718 discs. The cutting forces are predicted by a mechanistic model taking tool wear into account. The wear effect is expressed using the cumulative removed volume. The workpiece stiffness is determined with a reduced model using a modal basis. When dealing with large workpieces, it results in a remarkable computing time reduction during the time domain simulation. Cutting tests with varying engagements are simulated in a dexel-based versatile framework and undercut errors are compared to experimental observations.

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Instantaneous cutting-amount planning for machining deformation homogenization based on position-dependent rigidity of thin-walled surface parts

Cited by 41 publications

References 33 publications

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

Study of phenomena responsible for part distortions when turning thin Inconel 718 workpieces

A versatile approach, considering tool wear, to simulate undercut error when turning thin-walled workpieces

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