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Research Papers

Prediction of Form Errors in Rings of Nonuniform Cross Section Due to Workholding and Machining Loads

[+] Author and Article Information
Christopher L. Golden, Shreyes N. Melkote

George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332

J. Manuf. Sci. Eng 130(6), 061007 (Oct 10, 2008) (11 pages) doi:10.1115/1.2982274 History: Received February 09, 2008; Revised August 08, 2008; Published October 10, 2008

This paper presents a method for the prediction of final peak-to-valley (PTV) surface profile variation for face turning of rings of nonuniform cross section. An analytical method relates initial part form, part deflection during workholding and machining, and part elastic recovery to final PTV surface profile variation. Finite element method is used to supplement the analytical model, and experiments are conducted to validate both the analytical and finite element approaches. The analytical and finite element results correspond well with the experimental observations, with average relative errors of 11.6% and 7.2%, respectively.

Copyright © 2008 by American Society of Mechanical Engineers
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Figures

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Figure 1

Thin ring with nonuniform radial cross section

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Figure 2

Rotation of a ring cross section during toroidal deformation (10)

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Figure 3

Thin ring segment for analysis of toroidal deformation (plan view) (10)

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Figure 4

Toroidal angle versus angular position for W0=500 N m and R=39.8 mm

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Figure 5

Representation of taper cut across seal surface

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Figure 6

Schematic of cantilever loaded at free end (11)

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Figure 7

Representation of ring cross section for calculation of moment of inertia

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Figure 8

Flowchart describing calculation of final PTV surface profile variation

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Figure 9

Typical results of analytical model for (a) initial surface form profile, (b) clamped surface form profile, (c) machined surface form profile, and (d) final surface form profile (μm units); P=1.00 MPa, f=0.08 mm/rev, d=0.854 mm, and S=100 m/min

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Figure 10

Solid model assembly of cobalt-based alloy ring and chuck jaw sections

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Figure 11

Ring and chuck jaw sections meshed with SOLID185

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Figure 12

Typical results of finite element model for (a) initial surface form profile, (b) clamped surface form profile, (c) machined surface form profile, and (d) final surface form profile (μm units); P=1.00 MPa, f=0.08 mm/rev, d=0.854 mm, and S=100 m/min

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Figure 13

Experimental setup for measurement of initial PTV surface profile variation

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Figure 14

Experimental setup for measurement of clamped PTV surface profile variation

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Figure 15

Typical experimental results for (a) initial surface form profile, (b) clamped surface form profile, (c) machined surface form profile, and (d) final surface form profile (μm units); P=1.00 MPa, f=0.08 mm/rev, d=0.854 mm, and S=100 m/min

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Figure 16

(a) Scanned grayscale image of pressure sensitive film and (b) image of isolated pressure region

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Figure 19

Effect of depth of cut on final PTV surface profile variation

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Figure 18

Effect of feed on final PTV surface profile variation

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Figure 17

Effect of collet pressure on final PTV surface profile variation

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