The finite element formulation is studied in this paper to predict static form errors in the peripheral milling of complex thin-walled workpieces. Key issues such as cutter modeling, finite element discretization of cutting forces, tool–workpiece coupling and variation of the workpiece’s rigidity in milling are investigated. To be able to predict static form errors on the machined surface of complex form, considerable improvements are made on the proper modeling of the material removal in milling and the iterative calculations of tool-workpiece deflections. A general simulation approach is developed based on 3D irregular finite element meshes. By using illustrative examples, rigid and flexible models are compared with existing ones to show the validity of the approach.
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February 2005
Technical Papers
Numerical Prediction of Static Form Errors in Peripheral Milling of Thin-Walled Workpieces With Irregular Meshes
Min Wan,
Min Wan
Sino-French Laboratory of Concurrent Engineering, School of Electromechanics, Northwestern Polytechnical University, P.O. Box 552, 710072 Xi’an, Shaanxi, China
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Weihong Zhang,
Weihong Zhang
Sino-French Laboratory of Concurrent Engineering, School of Electromechanics, Northwestern Polytechnical University, P.O. Box 552, 710072 Xi’an, Shaanxi, China
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Kepeng Qiu,
Kepeng Qiu
Sino-French Laboratory of Concurrent Engineering, School of Electromechanics, Northwestern Polytechnical University, P.O. Box 552, 710072 Xi’an, Shaanxi, China
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Tong Gao,
Tong Gao
Sino-French Laboratory of Concurrent Engineering, School of Electromechanics, Northwestern Polytechnical University, P.O. Box 552, 710072 Xi’an, Shaanxi, China
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Yonghong Yang
Yonghong Yang
Xi’an Aircraft International Corporation, 710089 Xi’an, Shaanxi, China
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Min Wan
Sino-French Laboratory of Concurrent Engineering, School of Electromechanics, Northwestern Polytechnical University, P.O. Box 552, 710072 Xi’an, Shaanxi, China
Weihong Zhang
Sino-French Laboratory of Concurrent Engineering, School of Electromechanics, Northwestern Polytechnical University, P.O. Box 552, 710072 Xi’an, Shaanxi, China
Kepeng Qiu
Sino-French Laboratory of Concurrent Engineering, School of Electromechanics, Northwestern Polytechnical University, P.O. Box 552, 710072 Xi’an, Shaanxi, China
Tong Gao
Sino-French Laboratory of Concurrent Engineering, School of Electromechanics, Northwestern Polytechnical University, P.O. Box 552, 710072 Xi’an, Shaanxi, China
Yonghong Yang
Xi’an Aircraft International Corporation, 710089 Xi’an, Shaanxi, China
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received July 7, 2003; Revised March 1, 2004. Associate Editor: D.-W. Cho.
J. Manuf. Sci. Eng. Feb 2005, 127(1): 13-22 (10 pages)
Published Online: March 21, 2005
Article history
Received:
July 7, 2003
Revised:
March 1, 2004
Online:
March 21, 2005
Citation
Wan , M., Zhang, W., Qiu , K., Gao, T., and Yang, Y. (March 21, 2005). "Numerical Prediction of Static Form Errors in Peripheral Milling of Thin-Walled Workpieces With Irregular Meshes ." ASME. J. Manuf. Sci. Eng. February 2005; 127(1): 13–22. https://doi.org/10.1115/1.1828055
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