Prediction and compensation of geometrical errors in milling process of thin components using a flexible configuration setup

Abstract

In this study, a prediction model based on finite element analysis is developed to predict cutting errors during the machining process of thin plates using a flexible setup configuration. The model is based on analysis of the material deformation of thin plates under the action of axial cutting forces using a specifically designed test bed to reproduce commonly used flexible setup in industry. The cutting process is simplified as a static analysis of the material deformation under the effect of the applied cutting forces. In the analysis, different positions of the cutting tool during the machining process are studied to determine the workpiece’s geometrical profiles during milling. Several analyses are carried out for different positions of the cutting tool. The cutting force is also modeled to predict the cutting force for specific cutting conditions. This cutting force model is utilized as input to the finite element analysis of the material deformation of the workpiece during the machining process. The experimental system is also designed to conduct tests with different cutting conditions on the three-axis Huron K2X10 CNC milling machine to verify the predicted results obtained from the analysis model. The geometrical errors of the machined plates after machining are determined by using the Mitutoyo Bright Strato Coordinate Measurement Machine (CMM) to measure their geometrical profiles before and after machining processes. Finally, the mirror technique is utilized to compensate cutting deviations based on the predicted results of the workpiece’s displacements. Adding the value from the prediction model to the designed cutting depth creates the updated tool path. The results show good agreement in the prediction of the thin plate deformation during the machining as compared to the experimental tests.

Date	4 Feb 2016
Original language	American English
Awarding Institution	École de technologie supérieure
Supervisor	Jean-François Chatelain (Supervisor)