Machining error prediction scheme aided smart fixture development in machining of a Ti6Al4V slender part
Machining error prediction scheme aided smart fixture development in machining of a Ti6Al4V slender part
复制标题
DOI：
10.1177/09544054221136520
复制
发表时间：
2022-11-24
期刊：
影响因子：
2.6
通讯作者：
Ratchev, Svetan
中科院分区：
文献类型：
--
作者：
Liu, Shulong;Afazov, Shukri;Ratchev, Svetan
细长（低刚度）零件的加工与刀具/工件偏转有关，这是由于诱导切削力导致的加工误差（加工表面的尺寸不准确）。智能夹具的发展被视为减少加工误差的一个推动因素。为了缩短交付周期，需要通过使用更多的虚拟仿真和更少的物理迭代来有效地设计智能灯具。本文提出了一种新的方法，加工误差预测铣削夹具工件系统的发展。该方法集成了切削力模型，基于有限元的夹具工件系统和多步误差预测方法。该方法首先在柔性薄壁Ti6 Al 4V细长零件上进行了验证，预测和测量的加工误差之间的差异小于6%。预测和测量的切削力之间的差异约为6%。获得的信心后，该方法被应用到柔性薄壁Ti6 Al 4V细长件所包围的夹具与三个驱动器作为支持。预测的加工误差从0.2-0.33 mm（无致动器）的范围内减少到0.12-0.14 mm（有三个致动器）。这证明了所开发的方法的能力，以帮助未来的智能灯具的设计，以减少其开发过程中的交货时间的潜力。
Machining of slender (low rigidity) parts is associated with tool/workpiece deflections due to induced cutting forces resulting in machining error (dimensional inaccuracy of the machined surface). The development of smart fixtures is seen as an enabler for reduction of machining error. To reduce lead times, the smart fixtures need to be designed in an efficient way by using more virtual simulations and less physical iterations. This paper presents the development of a novel methodology for machining error prediction in milling of a fixture-workpiece system. The methodology integrates a cutting force model, a finite element based fixture-workpiece system and a multi-step error predictive approach. The methodology was first validated on a flexible thin-wall Ti6Al4V slender part where less than 6% difference was achieved between predicted and measured machining error. The difference between predicted and measured cutting forces was approximately 6%. After the gained confidence, the methodology was applied to the flexible thin-wall Ti6Al4V slender part encompassed by a fixture with three actuators acting as supports. The predicted machining error was reduced from the range of 0.2-0.33 mm (no actuators) to the range of 0.12-0.14 mm (with three actuators). This demonstrated the capability of the developed methodology to aid the design of future smart fixtures with the potential to reduce lead times during their development.