Virtual machining considering dimensional, geometrical and tool deflection errors in three-axis CNC milling machines

Soori, Mohsen; Arezoo, Behrooz; Habibi, Mohsen

doi:10.1016/j.jmsy.2014.04.007

Cited by 89 publications

(31 citation statements)

References 28 publications

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“…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.…”

Section: -Review Of Research Work In the Deflection Errors Of Thin mentioning

confidence: 99%

“…Where is the contact proportion of cutting edge with workpiece per revolution, is 33.98 for the HSS tools and 100.05 for the carbide tools, = 0.14, is cutting speed (mm/minutes) , = 0.28, is 0.15 for HSS tools while it reaches a maximum of 0.30 for carbide tools, and are slenderness ratio and chip cross-section which can be shown as Eq. (19) and Eq. (20) respectively [29].…”

Section: = (17)mentioning

confidence: 99%

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

Soori

Asmael

2020

Preprint

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To enhance accuracy as well as efficiency in process of machining operations, the virtual machining systems are developed. Free from surfaces of sophisticated parts such as turbine blades, airfoils, impellers, and aircraft components are produced by using the 5-axis CNC machine tools which can be analyzed and developed by using virtual machining systems. The machining operations of thin walled structures such as impeller blades are with deflection errors due to cutting forces and cutting temperatures. The flexibility of thin walled impeller blades can cause machining defects such as overcut or undercut. So, the desired accuracy in the machined impeller blades can be achieved by decreasing the deflection error in the machining operations. To minimize the deflection of machined impeller blades, optimized machining parameters can be obtained. An application of virtual machining system in predicting and minimizing the deflection errors of 5-Axis CNC machining operations of impeller blades is presented in the study to increase accuracy and efficiency in process of part production. The finite element analysis is applied to obtain the deflection error in machined impeller blades. In order to minimize the deflection error of impeller blades in the machining operations, the optimization methodology based on the Genetic algorithm is applied. The impeller is machined by using the 5-axis CNC machine tool in order to validate the developed virtual machining system in the study. Then, the machined impeller is measured by using the CMM machines to obtain the deflection error. As a result, the deflection error of in machining operations of impeller by using 5-Axis CNC machine tools can be decreased in order to enhance accuracy and efficiency of part manufacturing.

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Section: -Review Of Research Work In the Deflection Errors Of Thin mentioning

confidence: 99%

Section: = (17)mentioning

confidence: 99%

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

Soori

Asmael

2020

Preprint

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“…A virtual machining system by considering dimensional and geometrical errors of a three-axis CNC milling machine is presented by Soori et al (2013) to create actual machined parts in virtual environments. 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).…”

Section: Review Of the Research Workmentioning

confidence: 99%

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

Soori

Arezoo

Habibi

2017

IJCAT

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Accuracy of produced parts in machining process is influenced by many errors such as tool deflection as well as geometrical deviations of machine tool structure. To increase accuracy and productivity in part manufacturing, the errors are modelled by using mathematical concepts. This paper presents an application for the virtual machining systems to analyse accuracy in modelling of tool deflection error. A virtual machining system is used to create actual parts in virtual environments. Then, a comparison for different methods of tool deflection error such as cantilever beam model of the cutting tool, Finite Element Method (FEM) of the cutting tool and workpiece and geometrical model of the cutting tool effects on the workpiece is presented to show accuracy and reliability of the methods in prediction of milled surfaces. So, capabilities and difficulties of the methods in the error modelling are presented to increase accuracy and efficiency in part manufacturing.

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“…As a result, a reduction of testing and experiments on the shop floor can be achieved. Machining accuracy of CNC machines is under influence of many errors which causes differences between designed and produced parts [7].…”

Section: Introductionmentioning

confidence: 99%

Method for optimum calculus of machining parameters according to tool trajectories type based on milling process simulation

2017

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Original scientific paper Virtual manufacturing systems can provide useful means for products to be manufactured without the need of physical testing on the shop floor. As a result, the time and cost of part production can be decreased. The paper presents the influence of tool path trajectory on surface deviation geometry when finishing inclined surfaces. The aim of the study is to optimize the milling process taking into account the milling strategy. The research was focused on ball end finishing because it is well known that in plain cutting, in the centre of the flat mill the cutting speed is vc = 0 m/min. According to that, the surface roughness is influenced by the fact that in this area a friction process occurs and not a cutting process. Six types of tool trajectories were simulated and surface deviation was evaluated.

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Virtual machining considering dimensional, geometrical and tool deflection errors in three-axis CNC milling machines

Cited by 89 publications

References 28 publications

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

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

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

Method for optimum calculus of machining parameters according to tool trajectories type based on milling process simulation

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