A prediction of the machining defects in flank milling
Abstract: In peripheral milling with great axial engagements, the tool deflections generate some geometrical defects on the machined surface. This article present a prediction method of these defects which is applicable on every ruled surface. The cutting forces are estimate with the cutting pressure notion. The parameters of the tool/workpiece material couple are identified by a test part. The prediction of the tool deflections requires controlling the tool immersion angle for each angular position of the tool. The deflections can be significant. An original procedure which is based on an engagement cards avoids an iterative calculation of the radial engagement. The experimental checking of the method of prediction is presented in a test.
Summary (1 min read)
- By misnomer, the authors call the ''rough'' surface of the part the part surface before the tool passes.
- This raw part can be described by a CAD model or by a raw management dynamical system according to the tool paths during the preceding operations (NCSIMUL software  , Vericut software  and Delmia software  ).
3.2 The prediction algorithm in steady mode
- The tool crosses a transition zone (the zone where the engagement conditions rapidly vary), also known as Case 1.
- The tool enters the workpiece material (the initialisation of the calculation), also known as Case 2.
3.4 The tool input in the workpiece material
- Generally, in this first section, the tool is out of the workpiece material and there is no deformation.
- Criterion 5 is thus checked before passing to the following step.
5.3 The engagement line
- The maximum engagement card (Fig. 20 ) shows that on a section extracted from the steady mode phase the maximum immersion angle clearly increases then decreases when the generating point moves away from the embedding position.
- The authors see that the more significant the deformation is, the less the tool engages in the workpiece material as was described in paragraph 4.2.
- The method of prediction of peripheral milling defects proposed in this article is based on the estimation of the real tool engagement conditions.
- Several milling tests on different forms were carried out and made it possible to validate this method.
- The method rests on the precise analysis of the tool generating points kinematics.
- The authors research tasks now tend to exploit the concept of an engagement card within the framework of the machined tool paths generation by respecting a constant tool engagement in the workpiece material.
- Another objective is the direct compensation of the defects estimated by the model previously described, the objective being to machine a part by respecting the functional constraints which were initially defined.
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