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Research Papers

Tool Deflection Error of Three-Axis Computer Numerical Control Milling Machines, Monitoring and Minimizing by a Virtual Machining System

[+] Author and Article Information
Mohsen Soori

CAD/CAPP/CAM Research Center,
Department of Mechanical Engineering,
Amirkabir University of Technology
(Tehran Polytechnic),
424 Hafez Avenue,
Tehran 15875-4413, Iran
e-mail: mohsen.soori@gmail.com;
m.soori@aut.ac.ir

Behrooz Arezoo

CAD/CAPP/CAM Research Center,
Department of Mechanical Engineering,
Amirkabir University of Technology
(Tehran Polytechnic),
424 Hafez Avenue,
Tehran 15875-4413, Iran
e-mail: barezoo@yahoo.com; arezoo@aut.ac.ir

Mohsen Habibi

CAD/CAPP/CAM Research Center,
Department of Mechanical Engineering,
Amirkabir University of Technology
(Tehran Polytechnic),
424 Hafez Avenue,
Tehran 15875-4413, Iran
e-mail: mohsen.habibi.mech@gmail.com

1Corresponding author.

Manuscript received September 8, 2015; final manuscript received December 11, 2015; published online March 28, 2016. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 138(8), 081005 (Mar 28, 2016) (11 pages) Paper No: MANU-15-1465; doi: 10.1115/1.4032393 History: Received September 08, 2015; Revised December 11, 2015

Virtual manufacturing systems carry out the simulation of manufacturing processes in digital environment in order to increase accuracy as well as productivity in part production. There are different error sources in machine tools, such as tool deflection, geometrical deviations of moving axis, and thermal distortions of machine tool structures. The errors due to tool deflection are caused by cutting forces and have direct effects on dimensional accuracy, surface roughness of the parts, and efficient life of the cutting tool, holder, and spindle. This paper presents an application of virtual machining systems in order to improve the accuracy and productivity of part manufacturing by monitoring and minimizing the tool deflection error. The tool deflection error along machining paths is monitored to present a useful methodology in controlling the produced parts with regard to desired tolerances. Suitable tool and spindle can also be selected due to the ability of error monitoring. In order to minimize the error, optimization technique based on genetic algorithms is used to determine optimized machining parameters. Free-form profile of virtual and real machined parts with tool deflection error is compared in order to validate reliability as well as accuracy of the software.

Copyright © 2016 by ASME
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References

Figures

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Fig. 1

Dimensions of the end mill used in Eq. (1)

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Fig. 2

Mechanics and kinematics of the three-axis milling

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Fig. 3

Uncut chip thickness

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Fig. 4

Flowchart and strategy of machining parameters optimization by genetic algorithm

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Fig. 5

Dialog box of cutting forces

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Fig. 6

Dialog box of monitoring the tool deflection error

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Fig. 7

Dialog box of machining parameters optimizer

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Fig. 8

Measured cutting forces in slot milling tests, spindle speed 1000 rpm

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Fig. 9

Profile of the test workpiece

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Fig. 10

Original G-codes of test workpiece

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Fig. 11

Error enforced G-codes produced by the developed software

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Fig. 12

Distances between the profile of real machined part and nominal profile

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Fig. 13

Distances between the profile of virtual machined part and nominal profile

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Fig. 14

Distances between each point of real machined part with optimized machining parameters and nominal profile

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Fig. 15

Distances between each point of virtual machined part with optimized machining parameters and nominal profile

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Fig. 16

Comparison of the predicted cutting forces without and with optimization for five selected points along the profile of machined parts

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Fig. 17

Profile errors along the curve length

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