Skip to main content
SpringerLink
Log in

Machining simulation and system integration combining FE analysis and cutting mechanics modelling

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In this paper, the machining process to produce the right surface profile in machining low-rigidity parts is studied by considering moving dynamic cutting forces that statically and dynamically excite the tool and part reducing the validity of these packages’ output and leading to additional surface errors. The proposed approach is based on producing a simulation environment integrating a data model, an analytical force prediction model, a material removal model and an FE analysis commercial software package. This reported result focuses on the development of the simulation environment and the data model. The integrated environment provides a platform by which FE analysis commercial packages, ABAQUS, can exchange data with the proposed data model, force model and material removal model, to deliver new functionality for machining process simulation where there is force-induced part deflection. The data model includes complete mesh and analysis information for predicting part deflection and enables iterative data updating for multi-step simulation. The proposed simulation methodology has been experimentally validated.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Liu S, Soldatos KP (2002) On the improvement of transverse stress distributions in cross-ply laminated beams: advanced versus conventional beam theories. Int J Mech Sci 44:287–304

    Article  MATH  Google Scholar 

  2. Herranz1 S, Campa FJ, Lo’pez de Lacalle LN, Rivero1 A, Lamikiz A, Ukar1 E, Sa’nchez JA, Bravo U (2005) The milling of airframe components with low rigidity: a general approach to avoid static and dynamic problems. Proc I MECH E Part B J Eng Manuf 219(B11):789–802

    Google Scholar 

  3. Tsai J, Liao C (1999) Finite-element modelling of static surface errors in the peripheral milling of thin-walled workpiece. J Mater Process Technol 94:235–246

    Article  Google Scholar 

  4. Ratchev S, Nikov S, Moualek I (2002) Material removal simulation of peripheral milling of thin wall low-rigidity structure using FEA. Proceedings of the 35th CIRP international seminar on manufacturing systems, Seoul, Korea, 13–15 May pp 371–377

  5. Ratchev S, Liu S, Huang W, Becker AA (2004) Milling error prediction and compensation in machining of low-rigidity parts. Int J Mach Tools Manuf 44:1629–1641

    Article  Google Scholar 

  6. Ratchev S, Huang W, Liu S, Becker AA (2004) Modelling and simulation environment for machining of low-rigidity components. J Mater Process Technol 153–154:67–73

    Article  Google Scholar 

  7. Ratchev S, Liu S, Huang W, Becker AA (2006) An advanced FEA based force induced error compensation strategy in milling. Int J Mach Tools Manuf 46:542–551

    Article  Google Scholar 

  8. Suneel TS, Pande SS (2000) Intelligent tool path correction for improving profile accuracy in CNC turning. Int J Prod Res 38(14):3181–3202

    Article  MATH  Google Scholar 

  9. Mackerle J (1999) Finite-element analysis and simulation of machining: a bibliography (1976–1996). J Mater Process Technol 86:17–44

    Article  Google Scholar 

  10. Spence AD, Abrari F, Elbestawi MA (2000). Integrated solid modeller based solutions for machining. Comput Aided Des 32:553–568

    Article  Google Scholar 

  11. Tsai J, Liao C (1999) Finite-element modelling of static surface errors in the peripheral milling of thin-walled workpiece. J Mater Process Technol 94:235–246

    Article  Google Scholar 

  12. Marusich TD, Ortiz M (1995) Modelling and simulation of high speed machining. Int J Numer Methods in Eng 38:3675–3694

    Article  MATH  Google Scholar 

  13. ABAQUS 6.3. ABAQUS Inc, 1080 Main Street, Pawtucket, Rhode Island, 02860–4847, USA. http://www.abaqus.com

  14. Cho MS, Sim KS, Suk HC, Chang SK (2000) Static strength analysis of CANDU-6 reactor fuel bundle. Nucl Eng Des 200:407–419

    Article  Google Scholar 

  15. Zha Y, Moan T (2001) Ultimate strength of stiffened aluminium panels with predominantly torsional failure modes. Thin-Walled Struct 39:631–648

    Article  Google Scholar 

  16. Choi BK, Jerard RB (1998) Sculptured surface machining: theory and applications. Kluwer Academic, Dordrecht

    Google Scholar 

  17. Sagherian R, Elbestawi M (1990) A simulation system for improving machining accuracy in milling. Comput Ind 14:293–305

    Article  Google Scholar 

  18. Jang D, Kim K, Jung J (2000) Voxel-based virtual multi-axis machining. Int J Adv Manuf Technol 16:709–713

    Article  Google Scholar 

  19. Ratchev S, Nikov S, Moualek I (2002) Material removal simulation of peripheral milling of thin wall low-rigidity structure using FEA. Proceedings of the 35th CIRP international seminar on manufacturing systems, Seoul, Korea, 13–15 May pp 371–377

  20. Kline WA, DeVor RE, Shareef IA (1982) The prediction of surface accuracy in end milling. J Eng Ind 104:272–278

    Article  Google Scholar 

  21. Sutherland JW, DeVor RE (1986) An improved method for cutting force and surface error prediction in flexible end milling systems. J Eng Ind (Transaction of the ASME) 108:269–279

    Article  Google Scholar 

  22. Budak E, Altintas Y (1995) Modelling and avoidance of static form errors in peripheral milling of plates. Int J Mach Tools Manuf 35(3):476–495

    Article  Google Scholar 

  23. Feng HY, Menq C (1994) Prediction of cutting forces in the ball-end milling process-I: model formulation and model building procedure. Int J Mach Tools Manuf 34(5):697–710

    Article  Google Scholar 

  24. Merchant ME (1944) Basic mechanics of the metal citing process. ASME J Appl Mech A-168–175

    Google Scholar 

  25. Budak E, Altinrtas Y, Armarego EJA (1996) Prediction of milling force coefficients from orthogonal cutting data. ASME J Eng Ind 118:216–224

    Google Scholar 

  26. Altintas Y (2000) Manufacturing automation. Cambridge University Press

Download references

Author information

Authors and Affiliations

  1. School of Mechanical, Materials, Manufacturing Engineering, University of Nott ingham, Nottingham, NG7 2RD, UK

    Svetan Ratchev, Shulong Liu, Wei Huang & Adib A. Becker

Authors
  1. Svetan Ratchev
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Shulong Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Wei Huang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Adib A. Becker
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Shulong Liu.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Ratchev, S., Liu, S., Huang, W. et al. Machining simulation and system integration combining FE analysis and cutting mechanics modelling. Int J Adv Manuf Technol 35, 55–65 (2007). https://doi.org/10.1007/s00170-006-0700-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-006-0700-6

Keywords

Search

Navigation