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Surface Error Compensation in High Speed Machining of Thin Ribs

P, Pal Pandian and Sakthimurugan, K. and Raja, V.Prabhu (2010) Surface Error Compensation in High Speed Machining of Thin Ribs. Proceedings of International Conference on Recent Advances in Mechanical Engineering . p. 8.

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Machining of thin-walled parts is a key process in aerospace industry. Many components used in the aerospace industry are usually thin-walled structures. Because of their poor stiffness, thin-walled work pieces are very easy to deform under the action of cutting force in the process of cutting. Even in CNC milling, in which the tools are controlled exactly according to the contour of the thin-walled component, the wall will be thicker at the top and thinner at the root. In general, the surface error is induced mainly by the deflection of the work piece during milling, which does not remove the material as planned. The part deflection caused by the cutting force is difficult to predict and control. The main objective of this work is to compensate the surface error which is induced in machining of thin-walled components. This work involves three modules such as cutting force modeling, part deformation modeling and error compensation modeling. A predictive cutting force model has been developed and influence of cutting parameters on force components and chip thickness has been depicted as graphs using mathematical tool MathCAD 8 professional. The values of force components are validated by experiments using 8 channel kistler dynamometers and on-line/off-lone error measurement will be carried out using CMM/displacement sensors. Using the force model as input the deformation model has been developed in ANSYS 12.0 and influences unit linear load, cutter location and part thickness on deformation have been plotted as graphs. Finally, the error compensation profile will be drawn and simulated using an NC simulation tool VERICUT 6.0 experimental validation will also be done in order to compare the accuracy in dimensions of the component before and after error compensation. In future, a common error compensation strategy can be developed to integrate with the CNC simulation tools and adopted to industries.

Item Type:Article
Uncontrolled Keywords:High speed machining, Thin walled parts or Thin ribs, surface error, error compensation
Subjects:Publications > Publications by Faculty > Articles > Engineering
ID Code:1785
Deposited By:Knowledge Center Christ University
Deposited On:14 Dec 2011 13:29
Last Modified:30 Jul 2012 10:37

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