Milling Force Modeling of Thin-walled Parts with 5-Axis Flank Milling Considering Workpiece Deformation

doi:10.3901/JME.2022.07.317

Abstract

Abstract: Aiming at the problem that the time-varying nature of the contact relationship between workpiece and tool during machining can lead to inaccurate modeling of milling forces, a modeling method of five-axis flank milling forces under workpiece deformation is proposed. Firstly, based on the mechanical model of mechanical type II, the milling force model of micro-element is established by integrating the effects of shear force and plow cutting force. Secondly, the deformation of the workpiece at any depth of cut is calculated based on the Euler-Bernoulli beam theory. Then, the workpiece deformation is introduced into the modeling process and the covariates in the model are updated to establish a milling force model for thin-walled parts with five-axis flank milling considering the workpiece deformation. Finally, by comparing the experimental and model prediction results, it is concluded that the average peak errors of milling forces in X and Y directions are reduced by 4.42% and 0.62%, respectively, considering the deformation, which verified the validity of the model.

Key words: milling force modeling, workpiece deformation, five-axis flank milling, thin-walled parts

CLC Number:

TH161

WEI Xingchi, ZHAO Man, YANG Qingping, CAO Zhenzhen, MAO Jian. Milling Force Modeling of Thin-walled Parts with 5-Axis Flank Milling Considering Workpiece Deformation[J]. Journal of Mechanical Engineering, 2022, 58(7): 317-324.

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