TY - JOUR

T1 - Simulation of thermal and mechanical workpiece load

AU - Niederwestberg, D.

AU - Denkena, B.

N1 - Funding information: The presented results have been obtained within the research project “Thermomechanical Deformation of Complex Workpieces in Drilling and Milling Processes” (DE 447/90-2) within the DFG Priority Program 1480 “Modeling, Simulation and Compensation of Thermal Effects for Complex Machining Processes”. The authors would like to thank the German Research Foundation for its financial and organizational support of the project.

PY - 2014/8/22

Y1 - 2014/8/22

N2 - This paper presents a method for the simulation of thermal and mechanical load for arbitrary milling operations. In the first part of the paper the modeling of the NC-simulation based approach is presented. A new way of rotational tool modeling from detailed tool geometry representation including technological information about the real tool is shown. Further, the tool is intersected with a dexel discretized workpiece model. Based on this intersection, the contact zone is modeled and analyzed. In the next part of the paper the thermal and mechanical load of the workpiece is modeled. Therefore, for every intersection point a local discretized heat input and mechanical stress tensor representing the workpiece load are modeled based on the technological information stored in the rotational tool. Finally, the approach is verified by the comparison of resulting cutting forces during machining of a thin-walled workpiece. There is a significant correlation between the measured and simulated forces in magnitude and characteristic.

AB - This paper presents a method for the simulation of thermal and mechanical load for arbitrary milling operations. In the first part of the paper the modeling of the NC-simulation based approach is presented. A new way of rotational tool modeling from detailed tool geometry representation including technological information about the real tool is shown. Further, the tool is intersected with a dexel discretized workpiece model. Based on this intersection, the contact zone is modeled and analyzed. In the next part of the paper the thermal and mechanical load of the workpiece is modeled. Therefore, for every intersection point a local discretized heat input and mechanical stress tensor representing the workpiece load are modeled based on the technological information stored in the rotational tool. Finally, the approach is verified by the comparison of resulting cutting forces during machining of a thin-walled workpiece. There is a significant correlation between the measured and simulated forces in magnitude and characteristic.

KW - Cutting force

KW - Milling

KW - NC-simulation

KW - Thermo-mechanical load

KW - Workpiece load

UR - http://www.scopus.com/inward/record.url?scp=85027952762&partnerID=8YFLogxK

U2 - 10.1016/j.cirpj.2014.07.004

DO - 10.1016/j.cirpj.2014.07.004

M3 - Article

AN - SCOPUS:85027952762

VL - 7

SP - 315

EP - 323

JO - CIRP Journal of Manufacturing Science and Technology

JF - CIRP Journal of Manufacturing Science and Technology

SN - 1755-5817

IS - 4

ER -