Problem of Technological Deformations of Thin-Walled Workpieces During Milling
- Authors: Eremeykin P.A.1, Zhargalova A.D.1, Gavriushin S.S.1
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Affiliations:
- Issue: Vol 21, No 3 (2019)
- Pages: 17-27
- Section: TECHNOLOGY
- URL: https://bakhtiniada.ru/1994-6309/article/view/302037
- DOI: https://doi.org/10.17212/1994-6309-2019-21.3-17-27
- ID: 302037
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Full Text
Abstract
Introduction. Technologists often face the problem of thin-walled workpiece milling. Due to cutting forces the non-rigid workpiece deforms which leads to uneven material removal and surface deflection with respect to specified form. There are several technological tricks that allow to provide given quality parameters but commonly it imply additional material usage or require dedicated facility, so the existing means dramatically affect the total cost of the product. The purpose of the paper is to extend а new approach to thin-walled workpiece processing applying to milling process. The approach is called “soft” cutting modes and consists in using numerical modeling for specific technological conditions to select rational parameters of the cutting process. The modelling results are used to pick rational cutting modes that provide the specified quality on the one hand and are economically reasonable on the other hand. Early the software system was developed to simplify such cutting modes calculation for turning. This system can also be used to calculate modes for milling, but a milling model that takes into consideration the technological deformations is required. The paper considers the case of climb milling of thin rib with a cylindrical mill. Research methods: in the Abaqus system, a numerical FEM model for processing the workpiece is developed taking into account its compliance. Results and Discussion. The results are presented as 3D displacement fields, cutting force chart and result wall thickness colorful heatmap. Modelling results analysis allows to conclude that the workpiece flexibility immensely affects the wall final geometry. The obtained deflections are quite sophisticated and irregular that confirms the relevance of numerical modelling approach to predict milling accuracy.
About the authors
P. A. Eremeykin
Email: eremeykin@gmail.com
Ph.D. (Engineering) student, Mechanical Engineering Research Institute of the Russian Academy of Sciences, 4 Maly Kharitonievskiy Pereulok, Moscow, 101990, Russian Federation, eremeykin@gmail.com
A. D. Zhargalova
Email: azhargalova@bmstu.ru
Bauman Moscow State Technical University, 5 Baumanskaya 2-ya, Moscow, 105005, Russian Federation, azhargalova@bmstu.ru
S. S. Gavriushin
Email: gss@bmstu.ru
D.Sc. (Engineering), Professor; 1. Mechanical Engineering Research Institute of the Russian Academy of Sciences, 4 Maly Kharitonievskiy Pereulok, Moscow, 101990, Russian Federation; 2. Bauman Moscow State Technical University, 5 Baumanskaya 2-ya, Moscow, 105005, Russian Federation; gss@bmstu.ru
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