Simulation-based Correction Approach for Thermo-elastic Workpiece Deformations During Milling Processes

Glänzel, Janine; Herzog, Roland; Ihlenfeldt, Steffen; Meyer, Arnd; Unger, Roman

doi:10.1016/j.procir.2016.03.178

Cited by 3 publications

(2 citation statements)

References 2 publications

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“…FEM, can reach superior accuracies, but suffer from high computational efforts for large problems and often uncertain initial and boundary conditions describing thermal and mechanical loads on the workpiece. FEM approaches are used in particular for chipping process simulations [16][17][18][19]. As thermal boundary conditions can be undetermined and change during the inspection process in thermally uncontrolled environments they must be incorporated into the model, which is a non-trivial task.…”

Section: Thermoelastic Workpiece Modellingmentioning

confidence: 99%

Model-Based, Experimental Thermoelastic Analysis of a Large Scale Turbine Housing

Emonts¹,

Sanders²,

Montavon³

et al. 2022

Journal of Machine Engineering

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Temporally and spatially unstable thermal conditions lead to inhomogeneous thermoelastic changes in the workpiece geometry. Consequently, non-negligible geometric deviations are evident, especially when measuring large workpieces with narrow tolerances, which often take place in non-climatized production environments and thus make thermal monitoring indispensable. Accurate determination of the thermoelastic behaviour for complex and large geometries is a challenging task with computationally effortful or less accurate existing solutions. Thus, the development of innovative measurement and modelling approaches is subject of current research, whereat physical validation is a prerequisite. Therefore, the authors developed a method, enabling the emulation of typical process heat cycles on a turbine housing in combination with a geometric measurement system. The idea is to provide reproducible and reversible thermal conditions on a representative large workpiece and to investigate the resulting geometric deformation in an economically viable way. Throughout this study, an analogy test rig is presented, integrating different temperature sensors, two geometric measurement systems and thermal deformation models into one demonstrator. The demonstrator's first applications show insightful results, revealing accordance, but also unexpected deviations between the predicted and measured quantities. Moreover, it provides great potential for validation of more complex modelling approaches and innovative thermal condition monitoring systems for large precision workpieces.

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Section: Thermoelastic Workpiece Modellingmentioning

confidence: 99%

Model-Based, Experimental Thermoelastic Analysis of a Large Scale Turbine Housing

Emonts¹,

Sanders²,

Montavon³

et al. 2022

Journal of Machine Engineering

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“…To avoid these defects, the position error of the tool tip is predicted using finite elements (2). Another application of finite elements was used to identify the influence of thermoelastic deformations of the workpiece during the milling process (3).…”

Section: Introductionmentioning

confidence: 99%

Effects of Depth of Cut on Cylindrical Milling Process in Steel Casting: A Numerical Study

Salcedo¹,

Pealoza²,

Ochoa³

2018

IJCTR

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The complexity of the milling process has led us to study different parameters, among which are the cutting speed, feed speed, chip volume, cutting time and associated costs, which are the focus of this study. For this purpose, a calculation algorithm was designed in which fixed parameters were left and the cutting depth was varied from 2 to 8 mm. This resulted in an increase in process times and costs, which was expected due to the removal of more material and a negative impact on the surface finish of the part.

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Modeling, Simulation and Compensation of Thermomechanically Induced Material Deformation in Dry NC Milling Processes

Siebrecht

Wiederkehr

Zabel

et al. 2017

Lecture Notes in Production Engineering

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Simulation-based Correction Approach for Thermo-elastic Workpiece Deformations During Milling Processes

Cited by 3 publications

References 2 publications

Model-Based, Experimental Thermoelastic Analysis of a Large Scale Turbine Housing

Model-Based, Experimental Thermoelastic Analysis of a Large Scale Turbine Housing

Effects of Depth of Cut on Cylindrical Milling Process in Steel Casting: A Numerical Study

Modeling, Simulation and Compensation of Thermomechanically Induced Material Deformation in Dry NC Milling Processes

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