Numerical evaluation of cutting strategies for thin-walled parts
Abstract Static form errors due to in-process deflections is a major concern in flank milling of thin-walled parts. To increase both productivity and part geometric accuracy, there is a need to predict and control these form errors. In this work, a modelling framework for prediction of the cutting f...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Nature Portfolio
2024-01-01
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| Series: | Scientific Reports |
| Online Access: | https://doi.org/10.1038/s41598-024-51883-1 |
| _version_ | 1797350007004725248 |
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| author | Andreas Andersson Lassila Daniel Svensson Wei Wang Tobias Andersson |
| author_facet | Andreas Andersson Lassila Daniel Svensson Wei Wang Tobias Andersson |
| author_sort | Andreas Andersson Lassila |
| collection | DOAJ |
| description | Abstract Static form errors due to in-process deflections is a major concern in flank milling of thin-walled parts. To increase both productivity and part geometric accuracy, there is a need to predict and control these form errors. In this work, a modelling framework for prediction of the cutting force-induced form errors, or thickness errors, during flank milling of a thin-walled workpiece is proposed. The modelled workpiece geometry is continuously updated to account for material removal and the reduced stiffness matrix is calculated for nodes in the engagement zone. The proposed modelling framework is able to predict the resulting thickness errors for a thin-walled plate which is cut on both sides. Several cutting strategies and cut patterns using constant z-level finishing are studied. The modelling framework is used to investigate the effect of different cut patterns, machining allowance, cutting tools and cutting parameters on the resulting thickness errors. The framework is experimentally validated for various cutting sequences and cutting parameters. The predicted thickness errors closely correspond to the experimental results. It is shown from numerical evaluations that the selection of an appropriate cut pattern is crucial in order to reduce the thickness error. Furthermore, it is shown that an increased machining allowance gives a decreased thickness error for thin-walled plates. |
| first_indexed | 2024-03-08T12:38:33Z |
| format | Article |
| id | doaj.art-872bc1ab8e9447648e87a78408e4cb48 |
| institution | Directory Open Access Journal |
| issn | 2045-2322 |
| language | English |
| last_indexed | 2024-03-08T12:38:33Z |
| publishDate | 2024-01-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Scientific Reports |
| spelling | doaj.art-872bc1ab8e9447648e87a78408e4cb482024-01-21T12:18:54ZengNature PortfolioScientific Reports2045-23222024-01-0114111610.1038/s41598-024-51883-1Numerical evaluation of cutting strategies for thin-walled partsAndreas Andersson Lassila0Daniel Svensson1Wei Wang2Tobias Andersson3School of Engineering Science, University of SkövdeSchool of Engineering Science, University of SkövdeSchool of Engineering Science, University of SkövdeSchool of Engineering Science, University of SkövdeAbstract Static form errors due to in-process deflections is a major concern in flank milling of thin-walled parts. To increase both productivity and part geometric accuracy, there is a need to predict and control these form errors. In this work, a modelling framework for prediction of the cutting force-induced form errors, or thickness errors, during flank milling of a thin-walled workpiece is proposed. The modelled workpiece geometry is continuously updated to account for material removal and the reduced stiffness matrix is calculated for nodes in the engagement zone. The proposed modelling framework is able to predict the resulting thickness errors for a thin-walled plate which is cut on both sides. Several cutting strategies and cut patterns using constant z-level finishing are studied. The modelling framework is used to investigate the effect of different cut patterns, machining allowance, cutting tools and cutting parameters on the resulting thickness errors. The framework is experimentally validated for various cutting sequences and cutting parameters. The predicted thickness errors closely correspond to the experimental results. It is shown from numerical evaluations that the selection of an appropriate cut pattern is crucial in order to reduce the thickness error. Furthermore, it is shown that an increased machining allowance gives a decreased thickness error for thin-walled plates.https://doi.org/10.1038/s41598-024-51883-1 |
| spellingShingle | Andreas Andersson Lassila Daniel Svensson Wei Wang Tobias Andersson Numerical evaluation of cutting strategies for thin-walled parts Scientific Reports |
| title | Numerical evaluation of cutting strategies for thin-walled parts |
| title_full | Numerical evaluation of cutting strategies for thin-walled parts |
| title_fullStr | Numerical evaluation of cutting strategies for thin-walled parts |
| title_full_unstemmed | Numerical evaluation of cutting strategies for thin-walled parts |
| title_short | Numerical evaluation of cutting strategies for thin-walled parts |
| title_sort | numerical evaluation of cutting strategies for thin walled parts |
| url | https://doi.org/10.1038/s41598-024-51883-1 |
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