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Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation

With the continuous improvement of the performance of modern aerospace aircraft, the overall strength and lightweight control of aircraft has become a significant feature of modern aerospace parts. With the wide application of thin-walled parts, the requirements for dimensional accuracy and surface...

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Autores principales: Chen, Zhitao, Yue, Caixu, Liu, Xianli, Liang, Steven Y., Wei, Xudong, Du, Yanjie
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2021
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8707987/
https://www.ncbi.nlm.nih.gov/pubmed/34947274
http://dx.doi.org/10.3390/ma14247679
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author Chen, Zhitao
Yue, Caixu
Liu, Xianli
Liang, Steven Y.
Wei, Xudong
Du, Yanjie
author_facet Chen, Zhitao
Yue, Caixu
Liu, Xianli
Liang, Steven Y.
Wei, Xudong
Du, Yanjie
author_sort Chen, Zhitao
collection PubMed
description With the continuous improvement of the performance of modern aerospace aircraft, the overall strength and lightweight control of aircraft has become a significant feature of modern aerospace parts. With the wide application of thin-walled parts, the requirements for dimensional accuracy and surface quality of workpieces are increasing. In this paper, a numerical model for predicting surface topography of thin-walled parts after elastic deformation is proposed. In view of the geometric characteristics in the cutting process, the cutting force model of thin-walled parts is established, and the meshing relationship between the tool and the workpiece is studied. In addition, the influence of workpiece deformation is considered based on the beam deformation model. Cutting force is calculated based on deformed cutting thickness, and the next cutting–meshing relationship is predicted. The model combines the radial deflection of the workpiece in the feed direction and the changing meshing relationship of the tool–workpiece to determine the three-dimensional topography of the workpiece. The error range between the experimental and the simulation results of surface roughness is 7.45–13.09%, so the simulation three-dimensional morphology has good similarity. The surface topography prediction model provides a fast solution for surface quality control in the thin-walled parts’ milling process.
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spelling pubmed-87079872021-12-25 Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation Chen, Zhitao Yue, Caixu Liu, Xianli Liang, Steven Y. Wei, Xudong Du, Yanjie Materials (Basel) Article With the continuous improvement of the performance of modern aerospace aircraft, the overall strength and lightweight control of aircraft has become a significant feature of modern aerospace parts. With the wide application of thin-walled parts, the requirements for dimensional accuracy and surface quality of workpieces are increasing. In this paper, a numerical model for predicting surface topography of thin-walled parts after elastic deformation is proposed. In view of the geometric characteristics in the cutting process, the cutting force model of thin-walled parts is established, and the meshing relationship between the tool and the workpiece is studied. In addition, the influence of workpiece deformation is considered based on the beam deformation model. Cutting force is calculated based on deformed cutting thickness, and the next cutting–meshing relationship is predicted. The model combines the radial deflection of the workpiece in the feed direction and the changing meshing relationship of the tool–workpiece to determine the three-dimensional topography of the workpiece. The error range between the experimental and the simulation results of surface roughness is 7.45–13.09%, so the simulation three-dimensional morphology has good similarity. The surface topography prediction model provides a fast solution for surface quality control in the thin-walled parts’ milling process. MDPI 2021-12-13 /pmc/articles/PMC8707987/ /pubmed/34947274 http://dx.doi.org/10.3390/ma14247679 Text en © 2021 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Chen, Zhitao
Yue, Caixu
Liu, Xianli
Liang, Steven Y.
Wei, Xudong
Du, Yanjie
Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation
title Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation
title_full Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation
title_fullStr Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation
title_full_unstemmed Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation
title_short Surface Topography Prediction Model in Milling of Thin-Walled Parts Considering Machining Deformation
title_sort surface topography prediction model in milling of thin-walled parts considering machining deformation
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8707987/
https://www.ncbi.nlm.nih.gov/pubmed/34947274
http://dx.doi.org/10.3390/ma14247679
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