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Simulation of low rigidity part machining applied to thin-walled structures

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Abstract

The aim of this study is to evaluate the modelling of machining vibrations of thin-walled aluminium workpieces at high productivity rate. The use of numerical simulation is generally aimed at giving optimal cutting conditions for the precision and the surface finish needed. The proposed modelling includes all the ingredients needed for real productive machining of thin-walled parts. It has been tested with a specially designed machining test with high cutting engagement and taking into account all the phenomena involved in the dynamics of cutting. The system has been modelled using several simulation techniques. On the one hand, the milling process was modelled using a dynamic mechanistic model, with time domain simulation. On the other hand, the dynamic parameters of the system were obtained step by step by finite element analysis; thus the variation due to metal removal and the cutting edge position has been accurately taken into account. The results of the simulations were compared to those of the experiments; the discussion is based on the analysis of the cutting forces, the amplitude and the frequency of the vibrations evaluating the presence of chatter. The specific difficulties to perfect simulation of thin-walled workpiece chatter have been finely analysed.

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Authors and Affiliations

  1. ENIT (École Nationale d’Ingénieurs de Tarbes), LGP (Laboratoire Génie de Production), Université de Toulouse, 47 avenue d’Azereix, BP 1629, 65016, Tarbes Cedex, France

    Lionel Arnaud

  2. Manufacturing Processes Department, Fundación Tekniker-IK4, 20 Otaola hiribidea, 20600, Eibar, Gipuzkoa, Spain

    Oscar Gonzalo & Haritz Jauregi

  3. INSA, UPS, Mines Albi, ISAE; ICA (Institut Clément Ader), Université de Toulouse, 135 avenue de Rangueil, 31077, Toulouse Cedex 4, France

    Sébastien Seguy

  4. Société Mitis, École Centrale de Nantes, 1 rue de la Noë, 44321, Nantes, France

    Grégoire Peigné

Authors
  1. Lionel Arnaud
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  2. Oscar Gonzalo
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  3. Sébastien Seguy
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  4. Haritz Jauregi
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  5. Grégoire Peigné
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Corresponding author

Correspondence to Sébastien Seguy.

Additional information

Sadly, Grégoire Peigné died during the preparation of the article.

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Arnaud, L., Gonzalo, O., Seguy, S. et al. Simulation of low rigidity part machining applied to thin-walled structures. Int J Adv Manuf Technol 54, 479–488 (2011). https://doi.org/10.1007/s00170-010-2976-9

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  • DOI: https://doi.org/10.1007/s00170-010-2976-9

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