Obrabotka Metallov 2019 Vol. 21 No. 3

OBRABOTKAMETALLOV Vol. 21 No. 3 2019 26 TECHNOLOGY References 1. Budak E. Analytical models for high performance milling. Pt. 1. Cutting forces, structural deformations and tolerance integrity. International Journal of Machine Tools and Manufacture , 2005, vol. 46, no. 12–13, pp. 1478– 1488. DOI: 10.1016/j.ijmachtools.2005.09.009. 2. Masmali M., Mathew P.Application of a variable flow stress machining theory to helical end milling. Machining Science and Technology , 2018, vol. 22, no. 1, pp. 1–29. DOI: 10.1080/10910344.2017.1336182. 3. Huang Y., Zhang X., Xiong Y. Finite element analysis of machining thin-wall parts: error prediction and stability analysis. Finite element analysis: applications in mechanical engineering . Ed. by F. Ebrahimi. Rijeka, Croatia, InTech, 2012, pp. 327–354. DOI: 10.5772/50374. 4. Liu S., Ratchev S., Huang W., Becker A. Milling error prediction and compensation in machining of low- rigidity parts. International Journal of Machine Tools and Manufacture , 2004, vol. 44, no. 15, pp. 1629–1641. DOI: 10.1016/j.ijmachtools.2004.06.001. Problem of Technological Deformations of Thin-Walled Workpieces During Milling Petr Eremeykin 1, a,* , Ayagma Zhargalova 2, b , Sergei Gavriushin 1, 2, c 1 Mechanical Engineering Research Institute of the Russian Academy of Sciences, 4 Maly Kharitonievskiy Pereulok, Moscow, 101990, Russian Federation 2 Bauman Moscow State Technical University, 5 Baumanskaya 2-ya, Moscow, 105005, Russian Federation a https://orcid.org/0000-0001-6291-8309, eremeykin@gmail.com , b https://orcid.org/0000-0002-6251-1004, azhargalova@bmstu.ru , c https://orcid.org/0000-0002-6547-1351, gss@bmstu.ru Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2019 vol. 21 no. 3 pp. 17–27 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2019-21.3-17-27 Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov ARTICLE INFO Article history : Received: 14 June 2019 Revised: 15 July 2019 Accepted: 15 August 2019 Available online: 15 September 2019 Keywords : Modeling Milling Finite Element Analysis Technological deformation Thin-walled workpiece Cutting modes ABSTRACT Introduction. Technologists often face the problem of thin-walled workpiece milling. Due to cutting forces the non-rigid workpiece deforms which leads to uneven material removal and surface deflection with respect to specified form. There are several technological tricks that allow to provide given quality parameters but commonly it imply additional material usage or require dedicated facility, so the existing means dramatically affect the total cost of the product. The purpose of the paper is to extend а new approach to thin-walled workpiece processing applying to milling process. The approach is called “soft” cutting modes and consists in using numerical modeling for specific technological conditions to select rational parameters of the cutting process. The modelling results are used to pick rational cutting modes that provide the specified quality on the one hand and are economically reasonable on the other hand. Early the software system was developed to simplify such cutting modes calculation for turning. This system can also be used to calculate modes for milling, but a milling model that takes into consideration the technological deformations is required. The paper considers the case of climb milling of thin rib with a cylindrical mill. Research methods: in the Abaqus system, a numerical FEM model for processing the workpiece is developed taking into account its compliance. Results and Discussion. The results are presented as 3D displacement fields, cutting force chart and result wall thickness colorful heatmap. Modelling results analysis allows to conclude that the workpiece flexibility immensely affects the wall final geometry. The obtained deflections are quite sophisticated and irregular that confirms the relevance of numerical modelling approach to predict milling accuracy. For citation: Eremeykin P.A., Zhargalova A.D., Gavriushin S.S. Problem of technological deformations of thin-walled workpieces during milling. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science , 2019, vol. 21, no. 3, pp. 17– 27. DOI: 10.17212/1994-6309-2019-21.3-17-27. (In Russian). ______ * Corresponding author Eremeykin Petr A. , Post-graduate student Mechanical Engineering Research Institute of the Russian Academy of Sciences 4 Maly Kharitonievskiy Pereulok 101990, Moscow, Russian Federation Tel.: +7 (916) 662-57-38, e-mail: eremeykin@gmail.com