Deformation Analysis of Thin-Walled Workpiece under Multi-Stress Coupled Effect

2010 ◽  
Vol 426-427 ◽  
pp. 284-288
Author(s):  
Dong Lu ◽  
Guo Hua Qin ◽  
Yi Ming Rong ◽  
C.M. Peng
Keyword(s):  
Initial Stress ◽  
Coupled Model ◽  
Element Model ◽  
Milling Process ◽  
Machining Process ◽  
Deformation Analysis ◽  
Milling Force ◽  
Thin Walled ◽  
And Control ◽  
The Finite Element Model

This document Cutting stress coupled with clamping stress and initial stress affects the workpiece deformation. To analyze the workpiece deformation the initial stress model is developed. The finite element model of milling process is established and the milling force and milling heat is predicted. The multi-stress coupled model is developed and the workpiece deformation during machining process and deformation after fixtures released are predicted. This study is helpful to predict and control the deformation for thin-walled workpiece.

Deformation Analysis of Aero Thin-Walled Workpiece Under Multi-Stress Coupled Effect

2007 ◽  
Author(s):  
Dong Lu ◽  
Jianfeng Li ◽  
Yiming Rong ◽  
Jie Sun ◽  
Song Zhang ◽  
...  
Keyword(s):  
Initial Stress ◽  
Initial Conditions ◽  
Stable Condition ◽  
Coupled Model ◽  
Element Model ◽  
Milling Process ◽  
Deformation Analysis ◽  
Reaction Forces ◽  
Milling Forces ◽  
The Finite Element Model

Cutting stress coupled with clamping stress and initial stress affects the workpiece deformation. To predicate the workpiece deformation during machining, the multi-stress coupled model was developed. The finite element model of milling process is established and the milling forces were predicted. The predicated milling force, clamping force and initial stress were taken as initial conditions and were inputted into the multi-stress coupled model. Workpiece deformation during machining and reaction forces of locators were predicated. To maintain workpiece in a stable condition during machining, reaction forces of the locators when the cutting tool moving along the clamp side must be monitored.

Machining Allowance Optimal Distribution of Thin-Walled Structure Based on Deformation Control

2017 ◽  
Vol 868 ◽  
pp. 158-165 ◽  
Author(s):  
Yu Zhi Chen ◽  
Wei Fang Chen ◽  
Rui Jun Liang ◽  
Ting Feng
Keyword(s):  
Cutting Force ◽  
Element Model ◽  
Optimization Method ◽  
Milling Process ◽  
Machining Process ◽  
Machining Accuracy ◽  
Side Milling ◽  
Deformation Control ◽  
Thin Walled ◽  
Relationship Of

Multilayer cutting is widely used in finish machining process of thin-walled parts to improve the machining precision. The paper presents a cutting allowance optimization method using genetic algorithm to improve the machining quality and efficiency of thin-walled parts in the field of aerospace. Considering the coupling relationship of the deformation between the layers in layered milling, the parameterized finite element model of thin-walled parts in side milling process is established. The best relationship between the workpiece stiffness and the cutting force is determined though iterative calculations, and the deformation caused by the cutting force can be minimized. The results show that the optimized distribution of the depth of finishing cutting was better than the experience. The method proposed in this paper can reduce the deformation of the workpiece during the machining process, and thus improve the machining accuracy.

The Application of FEM Technology on the Deformation Analysis of the Aero Thin-Walled Frame Shape Workpiece

2006 ◽  
Vol 315-316 ◽  
pp. 174-179 ◽  
Author(s):  
H. Guo ◽  
Dun Wen Zuo ◽  
S.H. Wang ◽  
Min Wang ◽  
L.L. Xu ◽  
...  
Keyword(s):  
Complex Structure ◽  
Element Model ◽  
Deformation Analysis ◽  
Machining Accuracy ◽  
National Defense ◽  
Residual Stress Field ◽  
Machining Deformation ◽  
Thin Walled ◽  
And Control ◽  
Milling Forces

Many thin-walled structure components widely used in aero industries not only have complex structure and large size, but also need high machining accuracy. However, because of their poor rigidity, it is easy to bring machining deformation caused by the existence of the initial residual stresses, the fixing stresses, cutting forces and cutting heat. The difficulty in ensuring their machining accuracy becomes a big problem, so that how to effectively predict and control the machining deformation has become an important subject in the development and production of our national defense weapons. This paper established a 3-D Finite element model with consideration of milling forces, clamping forces and initial residual stress field. By using this model, machining deformation of thin-walled frame shape workpieces has been computed. The simulated results are compared with experimental data, and the correctness of the simulation is verified. The study is helpful to the prediction and the control of machining deformation for thin-walled parts.

Finite Element Analysis and Experimental of Milling Force for Aeronautical Thin-Walled Workpiece

2011 ◽  
Vol 328-330 ◽  
pp. 685-689
Author(s):  
Jin Yu ◽  
Yu Xiang Shi ◽  
Gui Wu Yang
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Element Model ◽  
Milling Force ◽  
Element Analysis ◽  
Mesh Method ◽  
Thin Walled ◽  
Rotating Load ◽  
The Finite Element Model ◽  
Simulation Time

Traveling load and rotating load can be applied to the tool on the basis of analyzing the relative position between tool and workpiece in assemble model of finite simulation, a finite element model based on trochoid-motion is built. In order to reduce the simulation time, the transition mesh method was used to optimize the finite element model. This paper considers performance parameter of the workpiece, and studied the variation regularities of milling force on the Aeronautical thin-walled by using ABAQUS. At last the experiment shows that the finite element model was verified to be feasible, and the result is reliable.

Milling Force Prediction for Circular Contour Machining

2014 ◽  
Vol 800-801 ◽  
pp. 243-248
Author(s):  
Kai Zhao ◽  
Zhan Qiang Liu
Keyword(s):  
Prediction Model ◽  
Milling Process ◽  
Machining Process ◽  
Curvature Radius ◽  
Force Model ◽  
Milling Force ◽  
Circular Contour ◽  
The Mean ◽  
Contour Machining ◽  
Matlab Programming

When machining the complex parts of aircraft engines, the milling force for the circular contour must be accurately predicted to reduce machining vibration. In this paper, the prediction model of the mean milling force per tooth during machining circular contour is developed. Firstly, the formulas of the entry angle, the exit angle and the equivalent feed per tooth are established through the analysis of circular contour milling process. Then, the equation of the mean milling force per tooth is deduced based on mechanistic force model during the circular contour machining process. Finally, the prediction model of mean milling force per tooth during machining circular contour is developed using MATLAB programming. The relationship between the milling force per tooth and surface curvature radius of the machined workpiece is also analyzed in this paper.

Stability Prediction during Thin-Walled Workpiece High-Speed Milling

2009 ◽  
Vol 69-70 ◽  
pp. 428-432 ◽  
Author(s):  
Qing Hua Song ◽  
Yi Wan ◽  
Shui Qing Yu ◽  
Xing Ai ◽  
J.Y. Pang
Keyword(s):  
High Speed ◽  
Dynamic Properties ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Milling Process ◽  
Machining Process ◽  
High Speed Milling ◽  
Thin Walled ◽  
Optimization Of Cutting Parameters ◽  
Free Material

A method for predicting the stability of thin-walled workpiece milling process is described. The proposed approach takes into account the dynamic characteristics of workpiece changing with tool positions. A dedicated thin-walled workpiece representative of a typical industrial application is designed and modeled by finite element method (FEM). The workpiece frequency response function (FRF) depending on tool positions is obtained. A specific 3D stability chart (SC) for different spindle speeds and different tool positions is then elaborated by scanning the dynamic properties of workpiece along the machined direction throughout the machining process. The dynamic optimization of cutting parameters for increasing the chatter free material removal rate and surface finish is presented through considering the chatter vibration and forced vibration. The investigations are compared and verified by high speed milling experiments with flexible workpiece.

Milling Process Monitoring Based on Vibration Analysis Using Hilbert-Huang Transform

2018 ◽  
Vol 12 (5) ◽  
pp. 688-698 ◽  
Author(s):  
Agus Susanto ◽  
Chia-Hung Liu ◽  
Keiji Yamada ◽  
Yean-Ren Hwang ◽  
Ryutaro Tanaka ◽  
...  
Keyword(s):  
Signal Processing ◽  
Feature Extraction ◽  
Process Monitoring ◽  
Signal Analysis ◽  
Vibration Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Hilbert Huang Transform ◽  
Thin Walled ◽  
Tool Damage

Vibration analysis is one method of machining process monitoring. The vibration obtained in machining is often nonlinear and of a nonstationary nature. Therefore, an appropriate signal analysis is needed for signal processing and feature extraction. In this research, vibrations obtained in the milling of thin-walled workpieces were analyzed using the Hilbert-Huang transform (HHT). The features obtained by the HHT served as machining-state indicators for machining process monitoring. Experimental results showed the effectiveness of the HHT method for detecting chatter and tool damage.

Optimization of Milling Process for Aluminum Alloy Frame Part Based on Milling Force Analysis

2014 ◽  
Vol 575 ◽  
pp. 437-441
Author(s):  
Yi Shu Hao ◽  
Guo Qing Tang ◽  
Meng Zhang
Keyword(s):  
Aluminum Alloy ◽  
Selection Method ◽  
Milling Process ◽  
Parameter Selection ◽  
Force Analysis ◽  
Milling Force ◽  
Finite Element Software ◽  
Milling Parameters ◽  
Machining Errors ◽  
Thin Walled

In order to solve the problem of size guarantee related to thin-walled structure in traditional milling parameter selection, specific aluminum alloy frame part contains curved surface and thin-walled structure is studied. Numerical analysis is used in milling parameter selection method. Machining errors are calculated and checked based on milling force analysis. The milling process is simulated using finite element software. And aluminum alloy frame part processing is optimized from the angle of milling parameters according to the simulation results. Optimized milling parameters scheme is acquired, the results show that both machining precision and efficiency of the frame part are improved.

The Finite Element Model of Discontinuous Rock Masses

2011 ◽  
Vol 243-249 ◽  
pp. 2948-2951 ◽  
Author(s):  
Heng Bin Wu ◽  
Ze Ping He
Keyword(s):  
Finite Element ◽  
Limit Equilibrium ◽  
Element Model ◽  
Discontinuous Deformation Analysis ◽  
Deformation Analysis ◽  
Sliding Surface ◽  
Discontinuous Deformation ◽  
Discontinuous Rock ◽  
Element Theory ◽  
The Finite Element Model

The traditional limit equilibrium theory could not consider the discontinuous property of rock slope, and the existing research methods for the discontinuous rock mass confined to the Discrete Element Method and Discontinuous Deformation Analysis. Based on the finite element theory, considering the strength reduction of the joint mechanical parameters, the slope stability with one or two sets joints are analyzed in this paper. The results show that, the sliding surface for one set joint slope is close to the joint dip, and the sliding surface for two sets joints slope is close to the control joint dip.

Simulation of End Milling for Weak-Rigidity Structural Parts of Aluminium Alloy in Aviation

2011 ◽  
Vol 201-203 ◽  
pp. 332-336
Author(s):  
Chun Lin Fu ◽  
Cong Kang Wang ◽  
Tie Gang Li ◽  
Wan Shan Wang
Keyword(s):  
High Speed ◽  
End Milling ◽  
Element Model ◽  
Milling Process ◽  
Milling Force ◽  
Drilling Tool ◽  
Structural Parts ◽  
Aluminum Alloy 7075 ◽  
End Milling Process ◽  
Lower Material

To resolve the problem of the parts deformation because of the milling force, a finite element model (FEM) of end milling process simulation in milling force field was established. On the base of FEM, we simulate the high-speed end milling type structure of aluminum alloy 7075 parts. We successfully predict the end milling force, obtain the effect between the upper and lower material to the milling force, and Mises stress and the tool length beyond the part.The simulation results show that the lower material can increase the milling force to upper, and upper material can decrease milling force to lower layer.The drilling tool length beyond the part is about 0.5 mm .

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