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Development of a hybrid model for the prediction of shape deviations in milling
Author(s) -
Gulpak M.,
Sölter J.
Publication year - 2016
Publication title -
materialwissenschaft und werkstofftechnik
Language(s) - English
Resource type - Journals
SCImago Journal Rank - 0.285
H-Index - 38
eISSN - 1521-4052
pISSN - 0933-5137
DOI - 10.1002/mawe.201600605
Subject(s) - residual stress , machining , distortion (music) , materials science , finite element method , surface integrity , thermal expansion , residual , thermal , structural engineering , mechanical engineering , engineering , composite material , computer science , algorithm , physics , amplifier , optoelectronics , cmos , meteorology
The productivity in machining of high precision components is limited among others by the achievable geometric accuracy. Shape deviations arise due to several mechanisms of which residual stresses and a varying material removal due to thermal expansion have been incorporated in a proposed hybrid model. The model is based on two initially separated sub models which require a set of experimentally obtained input parameters. Both sub models utilize the finite element method. Sub model 1 calculates the mechanic response of the workpiece loaded with a near surface residual stress field (source stresses) resulting from the interaction of tool and workpiece. Sub model 2 calculates the thermal expansion of the workpiece utilising a three‐dimensional simulation of a moving surface heat source. The resulting inhomogeneous material removal is superimposed with the calculated shape deviations from sub model 1. This work focuses on distortion caused by machining induced residual stresses which are modelled as source stresses (sub model 1). These so called source stresses can be calculated directly from the bending and torsion of machined specimens and represent the distortion potential of the face milling process. The results demonstrate a pronounced correlation between the obtained source stresses and the width of cut a e . They further indicate that a separation of the effects resulting from the removal of material containing workpiece inherent residual stresses and from the newly generated residual stresses in the machined surface layer is required for the calculation of machining induced residual stresses.