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A turning simulation environment for geometric error estimation of thin-walled parts

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Abstract

Machining of thin-walled parts is a key process in many industries such as aviation and marine and power engineering. During such machining operation, very aggressive cutting conditions such as large feed rate, higher cutting speed, and large depth of cut are used to achieve higher material removal rate. During machining, thin-walled workpiece faces significant elastic deformation due to higher cutting forces leading to dimensional and geometric inaccuracy to the component. The present research work aims to develop a multi-step and multi-level turning simulation environment for estimation of various geometric errors such as straightness, circularity, and cylindricity of thin-walled part. In the proposed simulation environment, various modules such as process geometry, cutting force, tool deflection, and surface error generation have been developed in MATLAB©. On the other end, the modules such as part geometry, workpiece deflection, and material removal are made using finite element analysis technique in APDL environment of the ANSYS© commercial software. The estimated 3D turned surface and concerned geometric errors can be obtained as outcomes of the simulation environment without conducting expensive actual machining operation for varying cutting conditions. In order to estimate geometric errors accurately, the combined effect of tangential and radial force components are equally important to take care of geometrical shape change and peripheral thinning of thin-wall parts. The proposed simulation environment can be used as a convenient and cost-effective tool for process planners and machining practitioners for adopting a suitable error compensation strategy. Machining experiments are performed further to conform the validity of simulation environment by comparing the predicted results to their measured counterparts.

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Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request. Most of the datasets are provided in this paper.

Abbreviations

\({ER}_{(i,j)}\) :

Radial error at ith feed station and jth incremental rotational position of job

\({R}_{(i,j)}\) :

Actual radius at ith feed station and jth incremental rotational position

\({\theta }_{(i,j)}\) :

Angular position of the cylinder

\({R}_{d}\) :

Desired radius of the turned job

\(i\) :

Index for feed station

\(j\) :

Index for incremental rotational position

\(n\) :

Finite number of feed station

\({R}_{od}\) :

Outer radius of hollow cylinder

\({R}_{id}\) :

Inner radius of hollow cylinder

\(L\) :

Length of hollow cylinder from fixed end

\(d\) :

Nominal depth of cut

\(f\) :

Nominal feed per revolution

\({f}_{r}\) :

Nominal feed rate

\(N\) :

Spindle RPM

\({\delta }_{wx}\) :

Workpiece deflection component X direction

\({\delta }_{tx}\) :

Tool deflection component in X direction

\({\delta }_{wy}\) :

Workpiece deflection component Y direction

\({\delta }_{ty}\) :

Tool deflection component in Y direction

\({\delta }_{ex}\) :

Effective deflection component in X direction

\({\delta }_{ey}\) :

Effective deflection component in Y direction

\({F}_{x}\) :

Normal force component

\({F}_{y}\) :

Tangential force component

\({F}_{z}\) :

Feed force component

\({F}_{T}\) :

Thrust force component

\({K}_{c}\) :

Cutting force constant for tangential force

\({K}_{f}\) :

Cutting force constant for feed force

\({K}_{C}\) :

Specific cutting force constant for tangential force

\({K}_{F}\) :

Specific cutting force constant for tangential force

\(p\) :

Constant used in power function

\(q\) :

Constant used in power function

\({K}_{tx}\) :

Tool stiffness along X direction

\({K}_{ty}\) :

Tool stiffness along Y direction

\(E\) :

Young’s modulus

\({I}_{zz}\) :

Moment of inertia about Z axis

\(B\) :

Width of tool

\(H\) :

Height of tool

\({N}_{1}\) :

Number of radial sections

\({N}_{2}\) :

Total number of job revolution

\({N}_{T}\) :

Total number of discrete points

\(\Delta \theta\) :

Angular step

\({S}_{t}E\) :

Straightness error

\({C}_{r}E\) :

Circularity error

\({C}_{y}E\) :

Cylindricity error

ER-1 :

The predicted radial error considering the effect of tangential and radial forces

ER-2 :

The predicted radial error considering the effect of radial force only

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Funding

This work is funded by the Science and Engineering Research Board (SERB), Department of Science and Technology (DST), Government of India (Project No: SB/FTP/ETA-03/2013).

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Authors and Affiliations

  1. Mechanical Engineering Department, Birla Institute of Technology and Science, Pilani, Rajasthan, 333031, India

    Hareendran Manikandan & Tufan Chandra Bera

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  1. Hareendran Manikandan
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  2. Tufan Chandra Bera
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Contributions

Hareendran Manikandan: original draft writing, investigation, performing experimentation, validation, resources, software. Tufan Chandra Bera: conceptualization, investigation, methodology, formal analysis, reviewing, supervision.

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Correspondence to Tufan Chandra Bera.

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Manikandan, H., Bera, T.C. A turning simulation environment for geometric error estimation of thin-walled parts. Int J Adv Manuf Technol 119, 789–809 (2022). https://doi.org/10.1007/s00170-021-08298-3

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