https://sam.ensam.eu:443 The DSpace digital repository system captures, stores, indexes, preserves, and distributes digital research material. Sun, 17 May 2026 08:39:15 GMT 2026-05-17T08:39:15Z http://hdl.handle.net/10985/15638 Prediction of form error during face turning on flexible Inconel 718 workpiece TOUBHANS, Bastien; VIPREY, Fabien; FROMENTIN, Guillaume; KARAOUNI, Habib Complex workpieces may contain thin sections that are more likely to deform during machining due to cutting forces. It may result in form errors on the final product. Then, it is important to anticipate such defects when programing tool paths. A mechanist formulation of the cutting forces model, considering tool wear, is proposed in association with a part flexibility model to determine elastic deformation during face turning of thin Inconel 718 discs. A specific experimental methodology has been developed to validate the simulation results by performing in-situ measurements of form error. Tue, 01 Jan 2019 00:00:00 GMT http://hdl.handle.net/10985/15638 2019-01-01T00:00:00Z TOUBHANS, Bastien VIPREY, Fabien FROMENTIN, Guillaume KARAOUNI, Habib Complex workpieces may contain thin sections that are more likely to deform during machining due to cutting forces. It may result in form errors on the final product. Then, it is important to anticipate such defects when programing tool paths. A mechanist formulation of the cutting forces model, considering tool wear, is proposed in association with a part flexibility model to determine elastic deformation during face turning of thin Inconel 718 discs. A specific experimental methodology has been developed to validate the simulation results by performing in-situ measurements of form error. http://hdl.handle.net/10985/16601 Analysis and modelling of trochoidal milling in Inconel 718 DUCROUX, Edouard; PRAT, David; VIPREY, Fabien; FROMENTIN, Guillaume; ALAIN, D'acunto Trochoidal path increases productivity, tool life and reduces cutting forces compare to classical slot milling. Consequently, this strategy is well adapted to improve the milling performance in refractory alloy such as Inconel 718. The tool path complexity affects the tool radial engagement and axes dynamic, so it appears difficulties to perform such strategy. Therefore, this article deals with an analytical approach of trochoidal modelling to determine the theoretical radial depth of cut, cut thickness, cutting forces and machine tool behavior in function of the different methods to program the trochoidal trajectory. Finally, this methodology allows the optimization of geometrical and kinematic parameters for trochoidal milling of Inconel 718. Tue, 01 Jan 2019 00:00:00 GMT http://hdl.handle.net/10985/16601 2019-01-01T00:00:00Z DUCROUX, Edouard PRAT, David VIPREY, Fabien FROMENTIN, Guillaume ALAIN, D'acunto Trochoidal path increases productivity, tool life and reduces cutting forces compare to classical slot milling. Consequently, this strategy is well adapted to improve the milling performance in refractory alloy such as Inconel 718. The tool path complexity affects the tool radial engagement and axes dynamic, so it appears difficulties to perform such strategy. Therefore, this article deals with an analytical approach of trochoidal modelling to determine the theoretical radial depth of cut, cut thickness, cutting forces and machine tool behavior in function of the different methods to program the trochoidal trajectory. Finally, this methodology allows the optimization of geometrical and kinematic parameters for trochoidal milling of Inconel 718. http://hdl.handle.net/10985/18996 Machinability of inconel 718 during turning: Cutting force model considering tool wear, influence on surface integrity TOUBHANS, Bastien; FROMENTIN, Guillaume; VIPREY, Fabien; KARAOUNI, Habib; DORLIN, Théo Machining accuracy can be compromised by elastic workpiece deformation and subsurface residual stress introduction during cutting. In order to anticipate the impact of cutting forces and surface integrity evolutions on finished surface and its geometrical errors, it is necessary to better understand the influence of cutting conditions and tool wear. In this study, machinability of Inconel 718 using a round carbide tool in finish turning conditions is assessed. Cutting forces evolution during tool life are analysed and accompanied by advanced investigations of cutting phenomena. An original mechanistic cutting force model is developed, identified and tested. It includes the effect of tool wear over time in its local formulation. This model allows predicting cutting forces evolution along tool pass for a wide range of finishing cutting conditions. Furthermore, a thorough analysis of residual stress profiles at different tool wear levels is led. It features quantitative results for fresh and worn tools. A study on the influence of cutting parameters and tool wear on residual stress profiles in the machining affected zone is highlighted. Wed, 01 Jan 2020 00:00:00 GMT http://hdl.handle.net/10985/18996 2020-01-01T00:00:00Z TOUBHANS, Bastien FROMENTIN, Guillaume VIPREY, Fabien KARAOUNI, Habib DORLIN, Théo Machining accuracy can be compromised by elastic workpiece deformation and subsurface residual stress introduction during cutting. In order to anticipate the impact of cutting forces and surface integrity evolutions on finished surface and its geometrical errors, it is necessary to better understand the influence of cutting conditions and tool wear. In this study, machinability of Inconel 718 using a round carbide tool in finish turning conditions is assessed. Cutting forces evolution during tool life are analysed and accompanied by advanced investigations of cutting phenomena. An original mechanistic cutting force model is developed, identified and tested. It includes the effect of tool wear over time in its local formulation. This model allows predicting cutting forces evolution along tool pass for a wide range of finishing cutting conditions. Furthermore, a thorough analysis of residual stress profiles at different tool wear levels is led. It features quantitative results for fresh and worn tools. A study on the influence of cutting parameters and tool wear on residual stress profiles in the machining affected zone is highlighted. http://hdl.handle.net/10985/25546 Novel in-situ methodology for geometric error characterisation of rotary axis errors on multi-axis machine tool. MALDONADO PIMIENTO, Daniel; VIPREY, Fabien; LAVERNHE, Sylvain; POULACHON, Gerard Complex mechanical parts with high geometry and dimensional accuracy require multi-axis machining with low volumetric errors. To achieve such precision in the micrometer range, the geometric errors of the machine tool must be correctly identified and compensated. This article proposes a new methodology to measure directly the geometric errors of the rotary axes on machine tool. The methodology consists of a system of several non-contact sensors that are strategically placed around a datum cylinder. This system is held on the machine spindle and remains static over the entire measurement. The relative motion between the sensors and the cylinder is obtained by rotating the table of the multi-axis machine tool. The cylinder could be fast centered and leveled by using micro linear stages. A rotation stage enables to decouple the rotary axis motion from the datum cylinder rotation, consequently carry out methodologies of errors separation associated with multiprobe and multistep methods. Tue, 14 Mar 2023 00:00:00 GMT http://hdl.handle.net/10985/25546 2023-03-14T00:00:00Z MALDONADO PIMIENTO, Daniel VIPREY, Fabien LAVERNHE, Sylvain POULACHON, Gerard Complex mechanical parts with high geometry and dimensional accuracy require multi-axis machining with low volumetric errors. To achieve such precision in the micrometer range, the geometric errors of the machine tool must be correctly identified and compensated. This article proposes a new methodology to measure directly the geometric errors of the rotary axes on machine tool. The methodology consists of a system of several non-contact sensors that are strategically placed around a datum cylinder. This system is held on the machine spindle and remains static over the entire measurement. The relative motion between the sensors and the cylinder is obtained by rotating the table of the multi-axis machine tool. The cylinder could be fast centered and leveled by using micro linear stages. A rotation stage enables to decouple the rotary axis motion from the datum cylinder rotation, consequently carry out methodologies of errors separation associated with multiprobe and multistep methods. http://hdl.handle.net/10985/26541 Geometric error compensation through position feedback modification and comparison of correction strategies in 3- axis machine-tool GUEVEL, Flore; VIPREY, Fabien; EUZENAT, Charly; FROMENTIN, GUILLAUME; MASCIANTONIO, Ugo In machine-tools, geometrical defects are unavoidable. They can greatly affect the dimensional accuracy of the final workpiece if not corrected. Software compensation strategies are less expensive than mechanical adjustments and they provide great improvement in volumetric accuracy. In this study, different compensation methods are compared in a 3-axis milling applications: Numerical Controller (NC) internal compensation tables, modification of the programmed tool-path (G code) and modification of position feedback signals. The latter is the main purpose of this work, because it shows great potential and is not linked to one particular type of NC. It communicates with a custom software application that processes the position data and generates corrected signals according to a geometric model based on the rigid body assumption. The NC is then induced to perform volumetric error correction based on its default programming. The compensation methods are compared based on their ability to bring out or correct imposed geometric errors. The highlighted solution shows performances comparable to the G-code modification by correcting more than 96% of the imposed geometric errors without affecting the numerical chain from the program generation to its execution on the machine. It is also independent of the NC or the motors control cards. Sun, 01 Jun 2025 00:00:00 GMT http://hdl.handle.net/10985/26541 2025-06-01T00:00:00Z GUEVEL, Flore VIPREY, Fabien EUZENAT, Charly FROMENTIN, GUILLAUME MASCIANTONIO, Ugo In machine-tools, geometrical defects are unavoidable. They can greatly affect the dimensional accuracy of the final workpiece if not corrected. Software compensation strategies are less expensive than mechanical adjustments and they provide great improvement in volumetric accuracy. In this study, different compensation methods are compared in a 3-axis milling applications: Numerical Controller (NC) internal compensation tables, modification of the programmed tool-path (G code) and modification of position feedback signals. The latter is the main purpose of this work, because it shows great potential and is not linked to one particular type of NC. It communicates with a custom software application that processes the position data and generates corrected signals according to a geometric model based on the rigid body assumption. The NC is then induced to perform volumetric error correction based on its default programming. The compensation methods are compared based on their ability to bring out or correct imposed geometric errors. The highlighted solution shows performances comparable to the G-code modification by correcting more than 96% of the imposed geometric errors without affecting the numerical chain from the program generation to its execution on the machine. It is also independent of the NC or the motors control cards. http://hdl.handle.net/10985/24550 MÉMOTVIT’ : L’apprentissage d’un champ lexical métier par les cartes : retours d’expériences GEOFFROY, Régine; TRUJILLO, Emmanuel; CHEVIGNARD, Christine; VIPREY, Fabien MEMOTVIT', un jeu de cartes comportant des définitions, permettant à des apprenants d'acquérir des connaissances sur des champs lexicaux inhérents à une discipline, et ce par le biais d'une activité ludique, en équipe. C'est un jeu qui sollicite l'intelligence individuelle et collective ainsi que les sens. L'objectif est de fournir à l'apprenant la capacité à connaître un champ lexical par contextualisation en équipe, puis une décontextualisassions individuelle et enfin une recontextualisation en équipe. L'apprenant peut évaluer son niveau de connaissance en s'autoévaluant grâce à une évaluation formative seul ou en groupe, un questionnaire en ligne. Tue, 04 Apr 2023 00:00:00 GMT http://hdl.handle.net/10985/24550 2023-04-04T00:00:00Z GEOFFROY, Régine TRUJILLO, Emmanuel CHEVIGNARD, Christine VIPREY, Fabien MEMOTVIT', un jeu de cartes comportant des définitions, permettant à des apprenants d'acquérir des connaissances sur des champs lexicaux inhérents à une discipline, et ce par le biais d'une activité ludique, en équipe. C'est un jeu qui sollicite l'intelligence individuelle et collective ainsi que les sens. L'objectif est de fournir à l'apprenant la capacité à connaître un champ lexical par contextualisation en équipe, puis une décontextualisassions individuelle et enfin une recontextualisation en équipe. L'apprenant peut évaluer son niveau de connaissance en s'autoévaluant grâce à une évaluation formative seul ou en groupe, un questionnaire en ligne. http://hdl.handle.net/10985/26511 Development and performance evaluation of real-time geometric error compensation through position feedback modification in 5-axis machining GUEVEL, Flore; VIPREY, Fabien; EUZENAT, Charly; FROMENTIN, GUILLAUME; MASCIANTONIO, Ugo Geometric errors in amachine tool structure are mainly responsible for the volumetric error in theworkspace. They occur at the attachment of each link between axis joints, but also along each axis in their joint frame. Reducing the impact of these errors is a key factor in guaranteeing the functional requirements of high value-added parts. Unlike mechanical correction, software compensation strategies are often chosen for their ease of implementation and versatile nature. In this study, a correction method by modifying the position measurement in real time is introduced and compared to compensation tables. The reaction response of the numerical controller (NC) to the modification of its position feedback is studied, and a 5-axis machining experiment to validate the proposed solution is performed. The principle of the experiment is to impose a virtual volumetric error in the workspace by modifying a machining program, then to test separately the ability of compensation tables and the proposed method to correct the chosen virtual geometric errors. The aim is to obtain a corrected workpiece similar to the one machined with a nominal program. In this way, it is not necessary to identify the geometric errors of the machine’s structure to test the performance of software compensationmethods. The machined workpieces feature geometries that are easy to control, but the tool paths generated to produce them were complex enough to challenge the compensation methods. The ability of the proposed solution to correct the virtual volumetric error introduced by a modified machining program is evaluated at 98%. Indeed, roundness measurements show that over 99% of the added error has been corrected, with residuals lower than 5 μm. Furthermore, the joint trajectories monitored during machining are studied through a contouring error estimation. Nominal and compensated trajectories are 98% similar with the proposed solution, compared with 35% for compensation tables. Wed, 09 Apr 2025 00:00:00 GMT http://hdl.handle.net/10985/26511 2025-04-09T00:00:00Z GUEVEL, Flore VIPREY, Fabien EUZENAT, Charly FROMENTIN, GUILLAUME MASCIANTONIO, Ugo Geometric errors in amachine tool structure are mainly responsible for the volumetric error in theworkspace. They occur at the attachment of each link between axis joints, but also along each axis in their joint frame. Reducing the impact of these errors is a key factor in guaranteeing the functional requirements of high value-added parts. Unlike mechanical correction, software compensation strategies are often chosen for their ease of implementation and versatile nature. In this study, a correction method by modifying the position measurement in real time is introduced and compared to compensation tables. The reaction response of the numerical controller (NC) to the modification of its position feedback is studied, and a 5-axis machining experiment to validate the proposed solution is performed. The principle of the experiment is to impose a virtual volumetric error in the workspace by modifying a machining program, then to test separately the ability of compensation tables and the proposed method to correct the chosen virtual geometric errors. The aim is to obtain a corrected workpiece similar to the one machined with a nominal program. In this way, it is not necessary to identify the geometric errors of the machine’s structure to test the performance of software compensationmethods. The machined workpieces feature geometries that are easy to control, but the tool paths generated to produce them were complex enough to challenge the compensation methods. The ability of the proposed solution to correct the virtual volumetric error introduced by a modified machining program is evaluated at 98%. Indeed, roundness measurements show that over 99% of the added error has been corrected, with residuals lower than 5 μm. Furthermore, the joint trajectories monitored during machining are studied through a contouring error estimation. Nominal and compensated trajectories are 98% similar with the proposed solution, compared with 35% for compensation tables. http://hdl.handle.net/10985/24682 Characterization of the clamping and internal residual stresses effects on the distortion of Inconel 718 parts resulting from turning RANCHIN, Lucas; VIPREY, Fabien; FROMENTIN, Guillaume; MONTEIRO, Eric; LORONG, Philippe; KARAOUNI, Habib; DORLIN, Théo The understanding of phenomena related to machining processesintheaerospace industry isstill the subject of study intheresearch community. This is due to the constrained geometric tolerances to ensure optimal performance and safety. Few studies have yet focused on the effect of the clamping sequence on part distortions during the machining process. Thus, the development of machining sequences, in particular the positioning of clamping points, still requires optimisation regarding the geometry to be machined. This contribution focuses on a first step of a study that aims to characterize workpiece distortions resulting from a multi-stageprocess in relation tothe clamping, cutting forcesand the initial ormachining induced stresses. To validate the approach, an insitu methodology for characterising the defects has been developed alongside a particular workpiece holder based on an industrial procedure is set up in order to observe and limit the part distortion along the whole process.The machining sequence is divided into two machining stepsseparated by unclampingand clampingoperations. Frontal axisymmetric grooves are machined in turning on both sides of a thin Inconel718 elementary disks. These operations are subject to in situ measurement on bothside of the workpiece. A laser profilometer and laser point sensorsare usedbetween each pass and at each stage of the machining sequenceoperation. The collected data will beused in a next step to validate a numerical model that predicts the evolution of the distortions of the part during the entire machining process Mon, 11 Dec 2023 00:00:00 GMT http://hdl.handle.net/10985/24682 2023-12-11T00:00:00Z RANCHIN, Lucas VIPREY, Fabien FROMENTIN, Guillaume MONTEIRO, Eric LORONG, Philippe KARAOUNI, Habib DORLIN, Théo The understanding of phenomena related to machining processesintheaerospace industry isstill the subject of study intheresearch community. This is due to the constrained geometric tolerances to ensure optimal performance and safety. Few studies have yet focused on the effect of the clamping sequence on part distortions during the machining process. Thus, the development of machining sequences, in particular the positioning of clamping points, still requires optimisation regarding the geometry to be machined. This contribution focuses on a first step of a study that aims to characterize workpiece distortions resulting from a multi-stageprocess in relation tothe clamping, cutting forcesand the initial ormachining induced stresses. To validate the approach, an insitu methodology for characterising the defects has been developed alongside a particular workpiece holder based on an industrial procedure is set up in order to observe and limit the part distortion along the whole process.The machining sequence is divided into two machining stepsseparated by unclampingand clampingoperations. Frontal axisymmetric grooves are machined in turning on both sides of a thin Inconel718 elementary disks. These operations are subject to in situ measurement on bothside of the workpiece. A laser profilometer and laser point sensorsare usedbetween each pass and at each stage of the machining sequenceoperation. The collected data will beused in a next step to validate a numerical model that predicts the evolution of the distortions of the part during the entire machining process http://hdl.handle.net/10985/20676 A versatile approach, considering tool wear, to simulate undercut error when turning thin-walled workpieces TOUBHANS, Bastien; LORONG, Philippe; VIPREY, Fabien; FROMENTIN, Guillaume; KARAOUNI, Habib In-process workpiece elastic deflection is the major source of geometrical error when machining low-stiffness workpieces. It creates an undercut error which needs to be corrected by time-consuming and labour-intensive operations. For this reason, cutting process simulation is growing in interest. To do so, a model representing the workpiece flexibility is coupled with a model to predict the applied cutting forces. For a given tool-material set, these cutting forces depend on the cut section, which therefore depends on current deflection of the part during machining, but also on the level of tool wear. This research work focuses on developing a general coupling approach to tackle this challenge. The case study is the finish turning on thin Inconel 718 discs. The cutting forces are predicted by a mechanistic model taking tool wear into account. The wear effect is expressed using the cumulative removed volume. The workpiece stiffness is determined with a reduced model using a modal basis. When dealing with large workpieces, it results in a remarkable computing time reduction during the time domain simulation. Cutting tests with varying engagements are simulated in a dexel-based versatile framework and undercut errors are compared to experimental observations. Fri, 01 Jan 2021 00:00:00 GMT http://hdl.handle.net/10985/20676 2021-01-01T00:00:00Z TOUBHANS, Bastien LORONG, Philippe VIPREY, Fabien FROMENTIN, Guillaume KARAOUNI, Habib In-process workpiece elastic deflection is the major source of geometrical error when machining low-stiffness workpieces. It creates an undercut error which needs to be corrected by time-consuming and labour-intensive operations. For this reason, cutting process simulation is growing in interest. To do so, a model representing the workpiece flexibility is coupled with a model to predict the applied cutting forces. For a given tool-material set, these cutting forces depend on the cut section, which therefore depends on current deflection of the part during machining, but also on the level of tool wear. This research work focuses on developing a general coupling approach to tackle this challenge. The case study is the finish turning on thin Inconel 718 discs. The cutting forces are predicted by a mechanistic model taking tool wear into account. The wear effect is expressed using the cumulative removed volume. The workpiece stiffness is determined with a reduced model using a modal basis. When dealing with large workpieces, it results in a remarkable computing time reduction during the time domain simulation. Cutting tests with varying engagements are simulated in a dexel-based versatile framework and undercut errors are compared to experimental observations. http://hdl.handle.net/10985/19992 New mechanistic cutting force model for milling additive manufactured Inconel 718 considering effects of tool wear evolution and actual tool geometry DUCROUX, Edouard; FROMENTIN, Guillaume; VIPREY, Fabien; PRAT, David; ALAIN, D'acunto Inconel 718 is widely used in aircraft industry due to its properties. Nevertheless, its mechanical and chemical properties make it hard-to-cut. As a consequence, additive manufacturing is developed in order to get near net shape part before machining. Thus, this article presents a study on the machinability of the Inconel 718 obtained by additive manufacturing compare to one from wrought bar. Firstly, the machinability in milling is investigated through microstructure observation and cutting forces analysis, then a tool wear observations for both material are realised. Thereafter, novel formulations of cutting force model in milling are developed associated to precise treatment and identification process. Thus, the cutting forces are modelled with a mechanistic approach fully parameterized, and furthermore the tool geometry as well as the local forces model consider tool flank wear effect. This study shows that additive manufactured Inconel 718 are the easiest to machine and that considering tool geometry evolution considering tool wear improves the model precision. Fri, 01 Jan 2021 00:00:00 GMT http://hdl.handle.net/10985/19992 2021-01-01T00:00:00Z DUCROUX, Edouard FROMENTIN, Guillaume VIPREY, Fabien PRAT, David ALAIN, D'acunto Inconel 718 is widely used in aircraft industry due to its properties. Nevertheless, its mechanical and chemical properties make it hard-to-cut. As a consequence, additive manufacturing is developed in order to get near net shape part before machining. Thus, this article presents a study on the machinability of the Inconel 718 obtained by additive manufacturing compare to one from wrought bar. Firstly, the machinability in milling is investigated through microstructure observation and cutting forces analysis, then a tool wear observations for both material are realised. Thereafter, novel formulations of cutting force model in milling are developed associated to precise treatment and identification process. Thus, the cutting forces are modelled with a mechanistic approach fully parameterized, and furthermore the tool geometry as well as the local forces model consider tool flank wear effect. This study shows that additive manufactured Inconel 718 are the easiest to machine and that considering tool geometry evolution considering tool wear improves the model precision.