Tool path planning and machining deformation compensation in high-speed milling for difficult-to-machine material thin-walled parts with curved surface

Gao, Yuanyuan; Ma, Jian-wei; Zhang, Jia; Wang, Fuji; Si, Likun; Song, De-Ning

doi:10.1007/s00170-015-7825-4

Cited by 76 publications

(12 citation statements)

References 17 publications

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“…The experiments were carried out according to the scheme of high-speed turn-milling that was the most interesting from the standpoint of roughness formation [15]. An engine lathe 16K20 that was equipped with a high-speed milling head.…”

Section: Description Of Theoretical and Experimental Studiesmentioning

confidence: 99%

Research of High-Speed Machining With Disk Cutters

et al. 2019

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At present, both preliminary and final HSM is recommended to be carried out according to the scheme of cut-down milling. Processing of reinforced and unreinforced polymers is also recommended to be carried out at cut-down travel. The main problem associated with cutdown milling is caused with insufficient dynamic stiffness or the presence of backlash in the feeder table. The proposed concept of machining allows eliminating fundamentally the influence of dynamic stiffness and the presence of backlash in the table feeding mechanism on the quality of machining with GUS makes it possible while retaining the advantages of cutdown milling. Some kinematic schemes for high-speed machining by milling and turnmilling are given in the paper. The schemes for forming geometrical roughness components in such machining and calculation formulas are presented. The results of experimental studies of roughness formation with disc cutters made of fiberglass composite material in high-speed machining are presented. The results obtained are compared with the calculated data.

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Section: Description Of Theoretical and Experimental Studiesmentioning

confidence: 99%

Research of High-Speed Machining With Disk Cutters

et al. 2019

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“…Some strategies are listed for improve the final surface topography [4]: (1) Changing machining strategy. Limiting cutting forces and adding sacrificial stiffeners can increase minimum stiffness, but they often lead to inefficient productivity [5].…”

Section: Introductionmentioning

confidence: 99%

Precise Machining Based on Ritz Non-uniform Allowances for Titanium Blade Fabricated by Selective Laser Melting

Zhang

Yuan

Wang

et al. 2021

Preprint

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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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“…Rai et al [8] proposed a validation model of milling process scheme based on finite element method to predict the deformation and elastic-plastic deformation of thin-walled parts by considering the influence of fixture, operation sequence, tool path and cutting parameters. Gao et al [9] obtained the combination of cutting parameters that directly affect the machining deformation, and proposed a strategy to control the deformation by planning the tool path and an effective compensation method based on modifying the tool point. Bolar et al [10] conducted full factor 3 4 test on Al 2024-T351, selected appropriate cutting parameters, and conducted variance analysis and regression analysis on the test to determine the influence of process parameters on workpiece roughness.…”

Section: Introductionmentioning

confidence: 99%

Vibration Control of Weakly Rigid Casing Based on Gasbag-rubber Damping Flexible Fixture

Zhu

Zhang

Tian

et al. 2021

Preprint

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Combustion chamber casing is a key component of aeroengine, because of its poor rigidity, severe chattering occurs during milling, which seriously affects the surface quality and processing efficiency of the casing, and the existence of geometric nonlinear problems in the machining process makes it difficult to predict machining vibration. Therefore, it is of great significance to study the vibration law of thin-walled casing and reduce machining vibration. Aiming at the problem of vibration control of thin-walled casing, this paper proposes a new type of gasbag-rubber damping flexible fixture, which differ from the ordinary rigid fixture, this fixture has adjustable clamping force and good vibration damping ability. The key factors affecting the vibration response of the thin-walled casing are studied through establishing an equivalent dynamic model of the workpiece-fixture system. The research results show that the gasbag-rubber damping flexible fixture can effectively provide support stiffness, which is beneficial to reduce the vibration of the workpiece during processing; According to the actual thickness of different workpieces, the appropriate gasbag pressure is recommended to give play to the vibration damping performance of the fixture; It is recommended that the thickness of the rubber damping block in practice is 8~12mm. The research work in this paper has important guiding significance for the design and use of the gasbag-rubber damping flexible fixture, and provides an effective theoretical prediction for the vibration of the thin-walled casing.

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Tool path planning and machining deformation compensation in high-speed milling for difficult-to-machine material thin-walled parts with curved surface

Cited by 76 publications

References 17 publications

Research of High-Speed Machining With Disk Cutters

Research of High-Speed Machining With Disk Cutters

Precise Machining Based on Ritz Non-uniform Allowances for Titanium Blade Fabricated by Selective Laser Melting

Vibration Control of Weakly Rigid Casing Based on Gasbag-rubber Damping Flexible Fixture

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