Journal ArticleDOI
The form error prediction in side wall machining considering tool deflection
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TLDR
In this article, an effective method for the form error prediction in side wall machining with a flat end mill is suggested, which can predict the surface form error accurately about 300 times faster than the previous method.Abstract:
In this research, an effective method for the form error prediction in side wall machining with a flat end mill is suggested. The form error is predicted directly from the tool deflection without surface generation by cutting edge locus with time simulation. The developed model can predict the surface form error accurately about 300 times faster than the previous method. Cutting forces and tool deflection are calculated considering tool geometry, tool setting error and machine tool stiffness. The characteristics and the difference of generated surface shape in up milling and down milling are discussed. The usefulness of the presented method is verified from a set of experiments under various cutting conditions generally used in die and mold manufacturing. This study contributes to real time surface shape estimation and cutting process planning for the improvement of form accuracy.read more
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Milling error prediction and compensation in machining of low-rigidity parts
TL;DR: In this paper, a new integrated methodology for modelling and prediction of surface errors caused by deflection during machining of low-rigidity components is proposed. But this approach is based on identifying and modelling key processing characteristics that influence part deflection, predicting the workpiece deflection through an adaptive flexible theoretical force-FEA deflection model and providing an input for downstream decision making on error compensation.
Journal ArticleDOI
An advanced FEA based force induced error compensation strategy in milling
TL;DR: In this paper, a multi-level machining error compensation approach focused on force-induced errors in machining of thin-wall structures is introduced, which takes into account the deflection of the part in different points of the tool path.
Journal ArticleDOI
Strategies for error prediction and error control in peripheral milling of thin-walled workpiece
TL;DR: In this article, the authors developed efficient strategies for controlling the force-induced surface dimensional errors in peripheral milling of thin-walled structures, where the focus was on how to select the feed per tooth and depth of cut simultaneously for tolerance specification and maximization of the feed each tooth simultaneously.
Journal ArticleDOI
Roughness and texture generation on end milled surfaces
TL;DR: In this paper, a flat end mill has an end cutting edge angle that plays an important role in surface texture, and the surface texture is produced by superposition of conical surfaces generated by the end-cutting edge rotation.
Journal ArticleDOI
Study on deformation of titanium thin-walled part in milling process
TL;DR: In this paper, the three-dimensional finite element models of a helical tool and a thin-walled part with a cantilever are established to predict the cutting deformation of a titanium alloy Ti6Al4V in milling process.
References
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Journal ArticleDOI
The prediction of cutting forces in end milling with application to cornering cuts
TL;DR: In this article, the authors present a mechanistic model for the force system in end milling, which is based on chip load, cut geometry, and the relationship between cutting forces and chip load.
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An Improved Method for Cutting Force and Surface Error Prediction in Flexible End Milling Systems
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The effect of runout on cutting geometry and forces in end milling
TL;DR: In this paper, mathematical models were developed for the cutting geometry, tooth radius, chip thickness and entry and exit angles for end milling with cutter offset or runout, which were merged with previously developed cutting force models to predict cutting force characteristics with cutter runout.