Simulation numérique de l'usinage à l'échelle macroscopique : modèles dynamiques de la pièceNumerical simulation of machining at the macroscopic scale: dynamic models of the workpiece

HAL is a multi-disciplinary open access archive for the deposit and dissemination of scientific research documents, whether they are published or not. The documents may come from teaching and research institutions in France or abroad, or from public or private research centers. L'archive ouverte pluridisciplinaire HAL, est destinée au dépôt et à la diffusion de documents scientifiques de niveau recherche, publiés ou non, émanant des établissements d'enseignement et de recherche français ou étrangers, des laboratoires publics ou privés. SummaryBlanking and machining are commonly used in processes to obtain the shape of many mechanical pieces. Although considerable number of experimental results exist, certain essential aspects of cutting are still not well understood. This comes from the complexity of the thermomechanical phenomena induced by the material separation as well as from the complexity of the dynamical behaviour of the whole workpiece/tool/machine system. Numerical simulations make it possible to go further in the comprehension and the prediction of machining and cutting processes. In this work the state-of-the art is analysed and we present the most recent developments in the contribution of computational mechanics to numerical simulation of machining and blanking. This contribution is, on one hand, developed at a very global scale called macroscopic scale. At this scale a representation of the deformations of the piece is necessary, for example when thin walls are present, and when both predictions of the geometrical state of final surface and/or stability of the process are expected. On the other hand, the contribution is also located at a more local scale: the mesoscopic scale. At this scale, the aim is the determination of thermomechanical sollicitations applied to the tool, the simulation of chip formation, or the description of residual states (mechanical, chemical) inside the workpiece after machining.

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Contribution of computational mechanics in numerical simulation of machining and blanking: State-of-the-Art

Lorong

Yvonnet

Coffignal

et al. 2006

Arch Computat Methods Eng

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Surface roughness variation of thin wall milling, related to modal interactions

Seguy

Dessein

Arnaud

2008

International Journal of Machine Tools and Manufacture

148

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High-speed milling operations of thin walls are often limited by the so-called regenerative effect that causes poor surface finish. The aim of this paper is to examine the link between chatter instability and surface roughness evolution for thin wall milling. Firstly, the linear stability lobes theory for the thin wall milling optimisation was used. Then, in order to consider the modal interactions, an explicit numerical model was developed. The resulting nonlinear system of delay differential equations is solved by numerical integration. The model takes into account the coupling mode, the modal shape, the fact that the tool may leave the cut and the ploughing effect. Dedicated experiments are carried out in order to confirm this modelling. This paper presents surface roughness and chatter frequency measurements. The stability lobes are validated by thin wall milling. Finally, the modal behaviour and the mode coupling give a new interpretation of the complex surface finish deterioration often observed during thin wall milling.

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Lobes de stabilité en UGV approche expérimentale en usinage de poches

Blanchard¹,

Rabany²,

Duc³

2005

Mécanique & Industries

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La théorie des lobes de stabilité en UGV est aujourd'hui maîtrisée pour des usinages suivant des trajectoires rectilignes età engagement radial constant. Pour des trajets contenant des arcs de cercles, le diagramme des lobes de stabilité en trajectoire rectiligne n'est plus applicable directement. L'étude expérimentale qui suit propose différentes options et réglages permettant d'utiliser les lobes de stabilité en usinage rectiligne dans le cadre de l'usinage de poches. Les options de programmation de la commande numérique, la consigne de vitesse d'avance et l'engagement radial sont plus particulièrementétudiés et optimisés pour obtenir des conditions les plus stables possibles.

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Simulation numérique de l'usinage à l'échelle macroscopique : modèles dynamiques de la pièceNumerical simulation of machining at the macroscopic scale: dynamic models of the workpiece

Cited by 3 publications

References 8 publications

Contribution of computational mechanics in numerical simulation of machining and blanking: State-of-the-Art

Contribution of computational mechanics in numerical simulation of machining and blanking: State-of-the-Art

Surface roughness variation of thin wall milling, related to modal interactions

Lobes de stabilité en UGV approche expérimentale en usinage de poches

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