Details
| Original language | English |
|---|---|
| Pages (from-to) | 340-345 |
| Number of pages | 6 |
| Journal | Procedia CIRP |
| Volume | 31 |
| Publication status | Published - 3 Jun 2015 |
| Event | 15th CIRP Conference on Modelling of Machining Operations, CMMO 2015 - Karlsruhe, Germany Duration: 11 Jun 2015 → 12 Jun 2015 |
Abstract
In this paper a model for a simulation based prediction of temperature induced shape deviations in dry milling is presented. A closed loop between Boolean material removal, process forces, heat flux and thermoelastic deformation is established. Therefore, an efficient dexel based machining simulation is extended by a contact zone analysis to model the local workpiece load. Based on the computed contact zone the cutting forces and heat flux are calculated using a semi-empirical process model. For a detailed consideration of the loads they are discretized and localized on the dexel-represented workpiece surface. A projection of the localized workpiece loads on the boundary of the finite element domain, taking into account the Boolean material removal during the process, allows the calculation of the current temperature and deformation of the workpiece. By transforming these thermomechanical characteristics back to the dexel-model a consideration in the machining simulation is possible. An extended contact zone analysis is developed for the prediction of the localized shape deviations. Finally, the results of the simulation are compared with measured data. The comparison shows that workpiece temperatures, workpiece deformation and shape deviations in different workpiece areas are predicted accurately.
Keywords
- Deformation, Dry milling, Finite element method (FEM), Geometric modelling, Material removal, Simulation, Thermal error
ASJC Scopus subject areas
- Engineering(all)
- Control and Systems Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Procedia CIRP, Vol. 31, 03.06.2015, p. 340-345.
Research output: Contribution to journal › Conference article › Research › peer review
}
TY - JOUR
T1 - Prediction of temperature induced shape deviations in dry milling
AU - Denkena, B.
AU - Schmidt, A.
AU - Maaß, P.
AU - Niederwestberg, D.
AU - Niebuhr, C.
AU - Vehmeyer, J.
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, MA 1657/21-2) within the DFG Priority Program 1480 ”Modeling, Simulation and Compensation of Thermal Effects for Complex Machining Processes”. The authors would like to thank the DFG for its financial and organizational support of the project.
PY - 2015/6/3
Y1 - 2015/6/3
N2 - In this paper a model for a simulation based prediction of temperature induced shape deviations in dry milling is presented. A closed loop between Boolean material removal, process forces, heat flux and thermoelastic deformation is established. Therefore, an efficient dexel based machining simulation is extended by a contact zone analysis to model the local workpiece load. Based on the computed contact zone the cutting forces and heat flux are calculated using a semi-empirical process model. For a detailed consideration of the loads they are discretized and localized on the dexel-represented workpiece surface. A projection of the localized workpiece loads on the boundary of the finite element domain, taking into account the Boolean material removal during the process, allows the calculation of the current temperature and deformation of the workpiece. By transforming these thermomechanical characteristics back to the dexel-model a consideration in the machining simulation is possible. An extended contact zone analysis is developed for the prediction of the localized shape deviations. Finally, the results of the simulation are compared with measured data. The comparison shows that workpiece temperatures, workpiece deformation and shape deviations in different workpiece areas are predicted accurately.
AB - In this paper a model for a simulation based prediction of temperature induced shape deviations in dry milling is presented. A closed loop between Boolean material removal, process forces, heat flux and thermoelastic deformation is established. Therefore, an efficient dexel based machining simulation is extended by a contact zone analysis to model the local workpiece load. Based on the computed contact zone the cutting forces and heat flux are calculated using a semi-empirical process model. For a detailed consideration of the loads they are discretized and localized on the dexel-represented workpiece surface. A projection of the localized workpiece loads on the boundary of the finite element domain, taking into account the Boolean material removal during the process, allows the calculation of the current temperature and deformation of the workpiece. By transforming these thermomechanical characteristics back to the dexel-model a consideration in the machining simulation is possible. An extended contact zone analysis is developed for the prediction of the localized shape deviations. Finally, the results of the simulation are compared with measured data. The comparison shows that workpiece temperatures, workpiece deformation and shape deviations in different workpiece areas are predicted accurately.
KW - Deformation
KW - Dry milling
KW - Finite element method (FEM)
KW - Geometric modelling
KW - Material removal
KW - Simulation
KW - Thermal error
UR - http://www.scopus.com/inward/record.url?scp=84939153762&partnerID=8YFLogxK
U2 - 10.1016/j.procir.2015.03.072
DO - 10.1016/j.procir.2015.03.072
M3 - Conference article
AN - SCOPUS:84939153762
VL - 31
SP - 340
EP - 345
JO - Procedia CIRP
JF - Procedia CIRP
SN - 2212-8271
T2 - 15th CIRP Conference on Modelling of Machining Operations, CMMO 2015
Y2 - 11 June 2015 through 12 June 2015
ER -