Modeling and experimental validation for surface error caused by axial cutting force in end-milling process

Selective Laser Melting (SLM) is an increasingly concerned trend in Ti-6Al-4V blade manufacturing, while the SLMed Ti-6Al-4V blade cannot be used directly because of poor surface integrity and high residual stresses. Precise machining after SLM is a feasible solution but also a challenge. The low rigidity of the blade will lead to deformation when machining. The deformation can lead to surface error and may make defect parts. Two-steps machining processes to address the problems were proposed in this paper. First, a non-uniform allowance distribution was allocated and optimized in semi-finishing based on Ritz solution to elastic deformation. The blade was simplified as a cantilever thin plate with various thickness, and the thickness of finishing allowance was designed and optimized on the premise of ensuring the thin-wall stiffness of the blade, so as to realize the design of Ritz non-uniform allowance. Then, finishing machining was conducted to achieve precise parts. A blade deformation model was established to evaluate surface error with cutting force moving and changing. Finite element analysis and experimental validation in ball-end milling of a blade were conducted. FEA results and experimental results showed dimensional errors have been reduced up to 50%. Further surface tests demonstrated that the mean surface roughness reduced from 7.88 μm to 0.815 μm. And the residual surface stresses of the SLM samples changed after semi-finishing machining due to the residual stress relaxation and redistribution. The results demonstrated that the proposed method enhanced the surface quality of blade fabricated by SLM.

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“…The following assumptions are made to simplify the calculation of defined the thin-walled blade workpiece [17]:…”

Section: Non-uniform Allowances Based On Machining Error Prediction M...mentioning

confidence: 99%

Precise machining based on Ritz non-uniform allowances for titanium blade fabricated by selective laser melting

Zhang

Yuan

Wang

et al. 2022

Int J Adv Manuf Technol

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“…Nevertheless, high speed combined with low rigidity makes easier the appearance of chatter. These vibrations can arise due to the system excitation at the natural frequency response of the cutting-tool or the workpiece or due to the amplification of the displacements caused by the forces and the lack of stiffness [31,32]. In these cases, the cut is unstable creating an un-constant chip thickness, which is afterwards reflected on the surface quality [33,34].…”

Section: Milling Of Aerospace Aluminum Alloysmentioning

confidence: 99%

Machining of Al-Cu and Al-Zn Alloys for Aeronautical Components

Salguero¹,

Sol²,

Gómez-Parra³

et al. 2021

Advanced Aluminium Composites and Alloys

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Machining operations are chosen by aircraft manufacturers worldwide to process light aluminum alloys. This type of materials presents good characteristics in terms of weight and physicochemical properties, which combined with a low cost ratio making them irreplaceable in aircraft elements with a high structural commitment. Conventional machining processes such as drilling, milling and turning are widely used for aeronautical parts manufacturing. High quality requirements are usually demanded for these kinds of components but aluminum alloys may present some machinability issues, basically associated to the heat generated during the process. Among others, surface quality and geometrical deviations are highly influenced by the condition of the cutting-tool, its wear and the cutting parameters. Consequently, the understanding of the relationship among the process parameters, the quality features and the main wear mechanism is a key factor for the improvement in the productivity. In this chapter, the fundamental issues of drilling, milling and turning are addressed, dealing with the relationship between cutting parameters, wear phenomena and micro and macro geometrical deviations.

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“…These instabilities are usually related to the tool vibrations produced during the machining but the most important one is the FRF of the part [17,25,27], which is constantly changing due to geometry variations. This cyclical behavior changes the FRF of the system and generates an unstable machining process [11,28]. Forced vibration or amplification takes place when the stiffness of the part is not enough to maintain a constant chip thickness.…”

Section: Type Of Parts and Associated Problemsmentioning

confidence: 99%

“…Others authors considered the tool position [49,70] and the fixture system [5]. Zhang et al [28] went further by including the effect of the distance to the clamping system.…”

Section: Computational Solutionsmentioning

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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Modeling and experimental validation for surface error caused by axial cutting force in end-milling process

Cited by 19 publications

References 33 publications

Precise machining based on Ritz non-uniform allowances for titanium blade fabricated by selective laser melting

Precise machining based on Ritz non-uniform allowances for titanium blade fabricated by selective laser melting

Machining of Al-Cu and Al-Zn Alloys for Aeronautical Components

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

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