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Non-uniform machining allowance planning method of thin-walled parts based on the workpiece deformation constraint

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Abstract

In order to reduce the machining deformation of thin-walled parts during milling, a non-uniform allowance planning method for thin-walled parts based on the workpiece deformation constraint with the idea of adding materials in reverse material removal sequence is proposed in this paper. This method does not require accurate deformation prediction and extensive experiments compared to traditional error compensation methods. It strives to maximize the allowance to enhance the stiffness of the in-process workpiece. First, a cutting force threshold calculation method is proposed according to the finite element method. The cutting force threshold at different positions is calculated by obtaining the local stiffness characteristics at the cutter-contact point under the constraint of allowable deformation. And then, the maximum machining allowance at the cutter-contact point is calculated depending on the cutting force model. Considering that the stiffness of the workpiece is position-dependent and affected by material removal, the stiffness of the workpiece is updated by adding elements in the reverse cutting direction, and the finishing stock is obtained by surface fitting. Experimental results show that compared with the traditional uniform allowance method, the error of the proposed method is reduced by about 83%, which can effectively reduce the deformation and improve the machining accuracy.

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Funding

This work is supported by grants from the National Natural Science Foundation of China (52005030) and the Industry-University-Research Collaboration project of China (HFZL2020CXY014-1).

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Authors and Affiliations

  1. School of Mechanical Electronic and Control Engineering, Beijing Jiaotong University, Beijing, China

    Zhengzhong Zhang, Yonglin Cai, Xiaolin Xi & Haitong Wang

  2. Key Laboratory of Vehicle Advanced Manufacturing, Measuring and Control Technology (Beijing Jiaotong University), Ministry of Education, Beijing, China

    Yonglin Cai & Haitong Wang

Authors
  1. Zhengzhong Zhang
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  2. Yonglin Cai
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  3. Xiaolin Xi
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  4. Haitong Wang
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Contributions

Zhengzhong Zhang proposed the method and carried out the experimental verification and result analysis. She also drafted the manuscript. Yonglin Cai discussed the study conception and experimental scheme. Xiaolin Xi contributed to the implementation of the algorithm. Yonglin Cai, Xiaolin Xi, and Haitong Wang commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Yonglin Cai.

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Zhang, Z., Cai, Y., Xi, X. et al. Non-uniform machining allowance planning method of thin-walled parts based on the workpiece deformation constraint. Int J Adv Manuf Technol 124, 2185–2198 (2023). https://doi.org/10.1007/s00170-022-10480-0

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  • DOI: https://doi.org/10.1007/s00170-022-10480-0

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