Tool Deflection Error of Three-Axis Computer Numerical Control Milling Machines, Monitoring and Minimizing by a Virtual Machining System

Abstract

Virtual manufacturing systems carry out the simulation of manufacturing processes in digital environment in order to increase accuracy as well as productivity in part production. There are different error sources in machine tools, such as tool deflection, geometrical deviations of moving axis, and thermal distortions of machine tool structures. The errors due to tool deflection are caused by cutting forces and have direct effects on dimensional accuracy, surface roughness of the parts, and efficient life of the cutting tool, holder, and spindle. This paper presents an application of virtual machining systems in order to improve the accuracy and productivity of part manufacturing by monitoring and minimizing the tool deflection error. The tool deflection error along machining paths is monitored to present a useful methodology in controlling the produced parts with regard to desired tolerances. Suitable tool and spindle can also be selected due to the ability of error monitoring. In order to minimize the error, optimization technique based on genetic algorithms is used to determine optimized machining parameters. Free-form profile of virtual and real machined parts with tool deflection error is compared in order to validate reliability as well as accuracy of the software.

Deflection Error Prediction and Minimization in 5-Axis Milling Operations of Thin-Walled Impeller Blades

“…Structural efficiency of a wind turbine blade is studied by Buckney et al [17] in order to improve designing process, minimizing weight and reducing the cost of wind energy. To analyze and modify the machining operations in virtual environments, virtual machining systems and applications is presented by Soori et al [18][19][20][21]. Virtual machining system and application is also presented by Altintas and Merdol [22] in order to obtain optimized condition of milling operations.…”

Accuracy analysis of tool deflection error modelling in prediction of milled surfaces by a virtual machining system

“…Soori et al (2014) presented virtual machining by considering dimensional, geometrical and tool deflection errors in three-axis CNC milling machines in order to create actual machined parts in the virtual environments. Application of virtual machining systems in monitoring and minimising the tool deflection error of three-axis CNC milling machines is presented by Soori et al (2016).…”

“…All of the research works on the tool deflection error presented so far have focused on the modelling as well as compensating the errors (Ratchev et al, 2003;Yun et al, 2002;Ikua et al, 2001;Habibi et al, 2011;Dépincé and Hascoët, 2006a). In order to decrease the tool deflection error in machining processes, optimisation techniques are also used in research works (Soori et al, 2016;Ong and Hinds, 2003;Merdol and Altintas, 2008). According to the author's findings, it was concluded that accuracy of the presented methods in tool deflection error modelling in comparison to the other methodologies were insufficiently explored in the previous works.…”

Reason Maintenance in Product Modelling via Open Source CAD System

“…Simulation techniques are becoming increasingly useful to help industries better manage their resources and not just for the educational benefit of the students. A method is provided for virtual machining which helps allocates errors in the design and manufacture of machine tools, diagnose the source of errors in machine tools and predict the accuracy of parts to be made on machine tools [10], [11]. The machining process and workpiece forming process can be observed directly in the virtual environment, so the correctness of the CAD/CAM code can be checked in advance to avoid the interference, collisions or other problems in the actual lathe processing and reduce the scrap rate of the workpiece and tool in the actual machining process.…”