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TECHNICAL PAPERS

Numerical Prediction of Static Form Errors in Peripheral Milling of Thin-Walled Workpieces With Irregular Meshes

[+] Author and Article Information
Min Wan, Weihong Zhang, Kepeng Qiu, 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

J. Manuf. Sci. Eng 127(1), 13-22 (Mar 21, 2005) (10 pages) doi:10.1115/1.1828055 History: Received July 07, 2003; Revised March 01, 2004; Online March 21, 2005
Copyright © 2005 by ASME
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References

Figures

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Cutting forces of Test 2. (a) Simulated values by different models; (b) deviations between the RM and the VRW; (c) predicted and experimental results from Ref. 10.
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Test 3. (a) Finite element discretization of curved workpiece; (b) overall form errors by the VRW.
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Cutting forces of Test 3. (a) Simulated values by different models; (b) deviations obtained by subtracting the VRW from the RM
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Form errors of Test 3 in two different positions. (a) Predicted values in cutting positions at 7.14 mm; (b) deviations between different models in (a); (c) predicted values in cutting positions at 35.7 mm; (d) deviations between different models in (c)
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Flowchart of error compensation process
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Cutter’s finite element model
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Coherence description of the cutter and the workpiece. (a) Milling of plane structure; (b) milling of curved surface structure.
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Illustration of the cutting force evaluation
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Illustration of the correction factor of the cutting force
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Cutting force discretization
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Corrections of element stiffness
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Modeling of the workpiece. (a) Mesh 1; (b) Mesh 2.
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Form errors of Test 1 in the middle position. (a) Predicted values of two meshes by the VRW; (b) deviation between the results produced from two meshes; (c) predicted and experimental results from Ref. 9.
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Form errors of Test 1 in the starting position. (a) Predicted values by different models; (b) deviations obtained by subtracting the VRW from the RM; (c) predicted and experimental results from Ref. 9.
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Overall form errors. (a) Results predicted by the VRW; (b) experimental results from Ref. 9.
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Form errors of Test 2 in the middle position. (a) Predicted values by different models; (b) deviations between different models; (c) predicted and experimental results from Ref. 10.

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