Systematic simulation procedure of peripheral milling process of thin-walled workpiece

Wan, Min; Zhang, W.H.; Tan, Guojin; Qin, Guohua

doi:10.1016/j.jmatprotec.2007.06.005

Cited by 47 publications

(13 citation statements)

References 19 publications

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“…for good surface roughness is about 1000 N and 100 mm/rev. 7. Surface roughness is found to be good in number of pass…”

Section: The Recommended Burnishing Force and Burnishing Feedmentioning

confidence: 91%

Finite Element Analysis of Milling Roller-Burnishing Process on Surface Integrity for Non-Ferrous Metal

Vishwakarma*,

Sharma

2019

IJRTE

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In today's world, large amount of attention is given to the surface roughness and surface micro hardness of the material as it's mechanical properties are greatly influenced by the surface finish. Surface Roughness is generally a measure of irregularities of the surface. It is essential to analyze the surface roughness of the material in order to avoid the failure of the material. A large number of parameters are involved analyzing the surface roughness such as type of tool, tool material, work piece material, machining operation, cutting parameters and cutting fluids. This paper aims to show that how surface roughness of the material reacts when different cutting parameters are adopted using face milling operation and how it reacts when finishing of the surface is done using roller burnishing operation experimentally and validate the results using FEM analysis using DEFORM 3D.

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“…for good surface roughness is about 1000 N and 100 mm/rev. 7. Surface roughness is found to be good in number of pass…”

Section: The Recommended Burnishing Force and Burnishing Feedmentioning

confidence: 91%

Finite Element Analysis of Milling Roller-Burnishing Process on Surface Integrity for Non-Ferrous Metal

Vishwakarma*,

Sharma

2019

IJRTE

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“…However, the geometric complexity of parts and the extreme machining performance of materials are challenging the current manufacturing capacity. Wan et al [141] established a set of system programs to simulate the peripheral milling process of thin-walled workpiece, which integrates the cutting force module composed of calculation of instantaneous uncut chip thickness, calibration of instantaneous cutting force coefficient, and cutting process module composed of calculation of cutting structure and static shape error, as shown in Figure 14. This method can be used to verify the rationality of the process and optimize the process parameters in the high-precision milling process.…”

Section: Uncut Chip Thicknessmentioning

confidence: 99%

Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

Duan

Ding

et al. 2021

Chin. J. Mech. Eng.

164

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Aluminum alloy is the main structural material of aircraft, launch vehicle, spaceship, and space station and is processed by milling. However, tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy. The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters, material mechanical properties, machine tools, and other parameters. In particular, milling force is the crucial factor to determine material removal and workpiece surface integrity. However, establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system. The research progress of cutting force model is reviewed from three modeling methods: empirical model, finite element simulation, and instantaneous milling force model. The problems of cutting force modeling are also determined. In view of these problems, the future work direction is proposed in the following four aspects: (1) high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth, which easily produces high residual stress. The residual stress should be analyzed under this particular condition. (2) Multiple factors (e.g., eccentric swing milling parameters, lubrication conditions, tools, tool and workpiece deformation, and size effect) should be considered comprehensively when modeling instantaneous milling forces, especially for micro milling and complex surface machining. (3) The database of milling force model, including the corresponding workpiece materials, working condition, cutting tools (geometric figures and coatings), and other parameters, should be established. (4) The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling. (5) The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication (mql) and nanofluid mql should be predicted.

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“…Comparable strategies of tool-path adjustments were pursued in further work [4][5][6]. For the prediction of mechanically-induced workpiece deformations of flexible parts, a variety of simulation approaches have been proposed in literature [7,8]. Rai and Xirouchakis [9] additionally integrated a heat input model to simulate thermally-induced workpiece deformations.…”

Section: Introductionmentioning

confidence: 99%

The Prediction of Surface Error Characteristics in the Peripheral Milling of Thin-Walled Structures

Wimmer

Zaeh

2018

JMMP

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Lightweight design is gaining in importance throughout the engineering sector, and with it, workpieces are becoming increasingly complex. Particularly, thin-walled parts require highly accurate and efficient machining strategies. Such low-rigidity structures usually undergo significant deformations during peripheral milling operations, thus suffering surface errors and a violation of tolerance specifications. This article introduces a general approach to mitigating surface errors during the peripheral milling of thin-walled aluminum workpieces. It incorporates an analytical approach to predicting surface-error characteristics based on geometrical quantities and process parameters, which is presented in detail. Milling experiments, including geometrical measurements of the samples, have been performed to verify the approach. The approach allows for a pre-selection of parameter sets that result in surface errors that can be compensated with minimal effort. Additionally, the introduced model offers a simple criterion to assess potential error mitigation by applying the respective tool-path adjustments. In doing so, the amount of costly numerical simulations or experiments is significantly reduced.

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Systematic simulation procedure of peripheral milling process of thin-walled workpiece

Cited by 47 publications

References 19 publications

Finite Element Analysis of Milling Roller-Burnishing Process on Surface Integrity for Non-Ferrous Metal

Finite Element Analysis of Milling Roller-Burnishing Process on Surface Integrity for Non-Ferrous Metal

Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis

The Prediction of Surface Error Characteristics in the Peripheral Milling of Thin-Walled Structures

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