Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation
With the continuous improvement of the performance of modern aerospace aircraft, the overall strength and lightweight control of aircraft has become a significant feature of modern aerospace parts. With the wide application of thin-walled parts, the requirements for dimensional accuracy and surface...
| Main Authors: | , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2021-12-01
|
| Series: | Materials |
| Subjects: | |
| Online Access: | https://www.mdpi.com/1996-1944/14/24/7679 |
| _version_ | 1797502702568079360 |
|---|---|
| author | Zhitao Chen Caixu Yue Xianli Liu Steven Y. Liang Xudong Wei Yanjie Du |
| author_facet | Zhitao Chen Caixu Yue Xianli Liu Steven Y. Liang Xudong Wei Yanjie Du |
| author_sort | Zhitao Chen |
| collection | DOAJ |
| description | With the continuous improvement of the performance of modern aerospace aircraft, the overall strength and lightweight control of aircraft has become a significant feature of modern aerospace parts. With the wide application of thin-walled parts, the requirements for dimensional accuracy and surface quality of workpieces are increasing. In this paper, a numerical model for predicting surface topography of thin-walled parts after elastic deformation is proposed. In view of the geometric characteristics in the cutting process, the cutting force model of thin-walled parts is established, and the meshing relationship between the tool and the workpiece is studied. In addition, the influence of workpiece deformation is considered based on the beam deformation model. Cutting force is calculated based on deformed cutting thickness, and the next cutting–meshing relationship is predicted. The model combines the radial deflection of the workpiece in the feed direction and the changing meshing relationship of the tool–workpiece to determine the three-dimensional topography of the workpiece. The error range between the experimental and the simulation results of surface roughness is 7.45–13.09%, so the simulation three-dimensional morphology has good similarity. The surface topography prediction model provides a fast solution for surface quality control in the thin-walled parts’ milling process. |
| first_indexed | 2024-03-10T03:39:52Z |
| format | Article |
| id | doaj.art-38c918acfa4e4b899e15f8bf9e0c0ed5 |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T03:39:52Z |
| publishDate | 2021-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-38c918acfa4e4b899e15f8bf9e0c0ed52023-11-23T09:21:27ZengMDPI AGMaterials1996-19442021-12-011424767910.3390/ma14247679Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining DeformationZhitao Chen0Caixu Yue1Xianli Liu2Steven Y. Liang3Xudong Wei4Yanjie Du5Key Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science and Technology, Harbin 150080, ChinaKey Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science and Technology, Harbin 150080, ChinaKey Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science and Technology, Harbin 150080, ChinaGeorgia Institute of Technology, George W. Woodruff School of Mechanical Engineering, Atlanta, GA 30332, USAKey Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science and Technology, Harbin 150080, ChinaKey Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science and Technology, Harbin 150080, ChinaWith the continuous improvement of the performance of modern aerospace aircraft, the overall strength and lightweight control of aircraft has become a significant feature of modern aerospace parts. With the wide application of thin-walled parts, the requirements for dimensional accuracy and surface quality of workpieces are increasing. In this paper, a numerical model for predicting surface topography of thin-walled parts after elastic deformation is proposed. In view of the geometric characteristics in the cutting process, the cutting force model of thin-walled parts is established, and the meshing relationship between the tool and the workpiece is studied. In addition, the influence of workpiece deformation is considered based on the beam deformation model. Cutting force is calculated based on deformed cutting thickness, and the next cutting–meshing relationship is predicted. The model combines the radial deflection of the workpiece in the feed direction and the changing meshing relationship of the tool–workpiece to determine the three-dimensional topography of the workpiece. The error range between the experimental and the simulation results of surface roughness is 7.45–13.09%, so the simulation three-dimensional morphology has good similarity. The surface topography prediction model provides a fast solution for surface quality control in the thin-walled parts’ milling process.https://www.mdpi.com/1996-1944/14/24/7679thin-walled partssurface topographychip thicknessmachining deformation |
| spellingShingle | Zhitao Chen Caixu Yue Xianli Liu Steven Y. Liang Xudong Wei Yanjie Du Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation Materials thin-walled parts surface topography chip thickness machining deformation |
| title | Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation |
| title_full | Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation |
| title_fullStr | Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation |
| title_full_unstemmed | Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation |
| title_short | Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation |
| title_sort | surface topography prediction model in milling of thin walled parts considering machining deformation |
| topic | thin-walled parts surface topography chip thickness machining deformation |
| url | https://www.mdpi.com/1996-1944/14/24/7679 |
| work_keys_str_mv | AT zhitaochen surfacetopographypredictionmodelinmillingofthinwalledpartsconsideringmachiningdeformation AT caixuyue surfacetopographypredictionmodelinmillingofthinwalledpartsconsideringmachiningdeformation AT xianliliu surfacetopographypredictionmodelinmillingofthinwalledpartsconsideringmachiningdeformation AT stevenyliang surfacetopographypredictionmodelinmillingofthinwalledpartsconsideringmachiningdeformation AT xudongwei surfacetopographypredictionmodelinmillingofthinwalledpartsconsideringmachiningdeformation AT yanjiedu surfacetopographypredictionmodelinmillingofthinwalledpartsconsideringmachiningdeformation |