TY - JOUR

T1 - Anticipatory Online Compensation of Tool Deflection Using a Priori Information from Process Planning

AU - Denkena, Berend

AU - Bergmann, Benjamin

AU - Schumacher, Tim

N1 - Funding Information: This research was funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation)?SFB 871/3?119193472.

PY - 2021/8/17

Y1 - 2021/8/17

N2 - Removing excess material from build-up welding by milling is a critical step in the repair of blades from aircraft engines. This so-called recontouring is a very challenging machining task. Shape deviations often result from the deflection of tool and workpiece due to process forces. Considering the individuality of repair cases, compensation of those deflections by process force measurement and online tool path adaption is a very suitable method. However, there is one caveat to this reactive approach. Due to causality, a corrective movement, following a force variation, is always delayed by a finite reaction time. At this moment, though, the displacement has already manifested itself as a deviation in the machined surface. To overcome those limitations and to improve compensation beyond the reduction of control delays, this study proposes a novel approach of anticipatory online compensation. Flank-milling experiments with abrupt changes in the tool-workpiece engagement conditions are conducted to investigate the limitations of reactive compensation and to explore the potential of the new anticipatory approach.

AB - Removing excess material from build-up welding by milling is a critical step in the repair of blades from aircraft engines. This so-called recontouring is a very challenging machining task. Shape deviations often result from the deflection of tool and workpiece due to process forces. Considering the individuality of repair cases, compensation of those deflections by process force measurement and online tool path adaption is a very suitable method. However, there is one caveat to this reactive approach. Due to causality, a corrective movement, following a force variation, is always delayed by a finite reaction time. At this moment, though, the displacement has already manifested itself as a deviation in the machined surface. To overcome those limitations and to improve compensation beyond the reduction of control delays, this study proposes a novel approach of anticipatory online compensation. Flank-milling experiments with abrupt changes in the tool-workpiece engagement conditions are conducted to investigate the limitations of reactive compensation and to explore the potential of the new anticipatory approach.

KW - Adaptive machining

KW - Compensation

KW - Electromagnetic guide

KW - Maintenance

KW - Repair

KW - Tool deflection

UR - http://www.scopus.com/inward/record.url?scp=85114745180&partnerID=8YFLogxK

U2 - 10.3390/JMMP5030090

DO - 10.3390/JMMP5030090

M3 - Article

AN - SCOPUS:85114745180

VL - 5

JO - Journal of Manufacturing and Materials Processing

JF - Journal of Manufacturing and Materials Processing

IS - 3

M1 - 90

ER -