An advanced machining simulation environment employing workpiece structural analysis

• Autorzy: Ratchev S. , Liu S. , Huang W. , Becker A. A.
• Języki publikacji: EN

Abstrakty

EN

Purpose: The study aims to reduce the surface dimensional error due to the part deflection during the machining of thin wall structures, thus, reduce machining costs and lead times by producing “right first time” components. Design/methodology/approach: The proposed simulation environment involves a data model, an analytical force prediction model, a material removal model and an FE analysis commercial software package. It focuses on the development of the simulation environment with a multi-level machining error compensation approach. Findings: The developed simulation environment can predict and reduce the form error, which is a limitation of the existing approaches. Research limitations/implications: The energy consumption, temperature change and residual stress are not studied in this research. Practical implications: The developed method provides a platform to deliver new functionality for machining process simulation. The convergence of the proposed integrated system can be achieved quickly after only a few iterations, which makes the methodology reliable and efficient. Originality/value: The study offers an opportunity to satisfy tight tolerances, eliminate hand-finishing processes and assure part-to-part accuracy at the right first time, which is a limitation of previous approaches.

Słowa kluczowe

EN

CAD/CAM; modelling; simulation; system integration; structural analysis

PL

CAD/CAM; modelowanie; symulacja; integracja systemu; analiza strukturalna

• Wydawca: International OCSCO World Press
• Czasopismo: Journal of Achievements in Materials and Manufacturing Engineering
• Rocznik: 2006
• Tom: Vol. 16, nr 1-2
• Strony: 139--144
• Opis fizyczny: Bibliogr. 16 poz., rys., tab., wykr.

Twórcy

autor

Ratchev S.

• School of Mechanical, Materials, Manufacturing Engineering, University of Nottingham, Nottingham, NG7 2RD, United Kingdom

autor

Liu S.

• School of Mechanical, Materials, Manufacturing Engineering, University of Nottingham, Nottingham, NG7 2RD, United Kingdom

autor

Huang W.

• School of Mechanical, Materials, Manufacturing Engineering, University of Nottingham, Nottingham, NG7 2RD, United Kingdom

autor

Becker A. A.

• School of Mechanical, Materials, Manufacturing Engineering, University of Nottingham, Nottingham, NG7 2RD, United Kingdom

Bibliografia

• [1] T. S. Suneel, S. S. Pande, Intelligent tool path correction for improving profile accuracy in CNC turning. International Journal of Production Research 2000;38(14):3181-3202.
• [2] J. Mackerle, Finite-element analysis and simulation of machining: a bibliography (1976-1996). Journal of Materials Processing Technology 1999; 86:17-44.
• [3] M. Rahman, J. Heikkala, K. Lappalainen, Modeling, measurement and error compensation of multi-axis machine tools. Part I: theory, International Journal of Machine Tools and Manufacture, 40 (2000) 1535-1546.
• [4] E. L. J. Bohez, Compensation for systematic errors in 5-axis NC machining, Computer-Aided Design 34 (2002) 391-403.
• [5] S. M. Wang, Y. L. Liu, Y. Kang, An efficient error compensation system for CNC multi-axis machines, International Journal of Machine Tools and Manufacture 42 (2002) 1235-1245.
• [6] M. Cho, T. Seo, H. Kwon, Integrated error compensation method using OMM system for profile milling operation, Journal of Materials Processing Technology 136 (2003) 88-99.
• [7] C. Raksiri, M. Parnichkun, Geometric and force errors compensation in a 3-axis CNC milling machine, International Journal of Machine Tools and Manufacture 44 (2004) 1283-1291.
• [8] S. Ratchev, S. Liu, W. Huang, and A. A. Becker, Milling error prediction and compensation in machining of low-rigidity parts, International Journal of Machine Tools and Manufacture, 44 (2004) 1629-1641.
• [9] S. Ratchev, S. Nikov, I. Moualek. Material removal simulation of peripheral milling of thin wall low-rigidity structure using FEA. Proceedings of the 35th CIRP international seminar on manufacturing systems, Seoul, Korea, 13-15 May 2002. p. 371-377.
• [10] S. Ratchev, W. Huang, S. Liu, and A. A. Becker, Modelling and simulation environment for machining of low-rigidity components, Journal of Materials Processing Technology 153-154 (2004) 67-73.
• [11] S. Ratchev, S. Liu, W. Huang, and A. A. Becker, An advanced FEA based force induced error compensation strategy in milling, International Journal of Machine Tools and Manufacture (In press).
• [12] VERICUT 5.2 User Manual, www.cgtech.com, Irvine, CA92618, 2002.
• [13] ABAQUS/Standard User’s Manual 6.1, Hibbitt, Karlsson and Sorensen, Inc., Pawtucket, RI 02860-4847, USA, 2000.
• [14] Third Wave Advant Edge, Third Wave Systems, Inc., USA., 2003
• [15] S. Ratchev, S. Liu, W. Huang and A. A. Becker, A flexible force model for end milling of low-rigidity parts, Journal of Materials Processing Technology 153-154 (2004) 134-138.
• [16] S. Ratchev, S. Liu, W. Huang and A. A. Becker, Error compensation strategy in milling flexible thin wall parts, Proceedings of the Advanced Materials & Processing Technologies 2005, Poland, 499-502.