A versatile approach, considering tool wear, to simulate undercut error when turning thin-walled workpieces
Article dans une revue avec comité de lecture
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.
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Communication avec acteTOUBHANS, Bastien; VIPREY, Fabien; FROMENTIN, Guillaume; KARAOUNI, Habib (Elsevier BV, 2019)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 ...
Article dans une revue avec comité de lectureTOUBHANS, Bastien; VIPREY, Fabien; FROMENTIN, Guillaume; KARAOUNI, Habib; DORLIN, Théo (Society of Manufacturing Engineers, 2020)Machining thin workpieces is a challenging task as geometrical errors may result from the combination of several phenomena. Among these, elastic workpiece deformation and machining induced residual stresses may be predominant ...
Machinability of inconel 718 during turning: Cutting force model considering tool wear, influence on surface integrity Article dans une revue avec comité de lectureTOUBHANS, Bastien; FROMENTIN, Guillaume; VIPREY, Fabien; KARAOUNI, Habib; DORLIN, Théo (Elsevier, 2020)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 ...
Investigations on the flank wear and modelling of the contact radius effect in turning of Ti6Al4V titanium alloy Communication avec acteBONO, Aurélie; DORLIN, Théo; COSTES, Jean-Philippe; FROMENTIN, Guillaume; KARAOUNI, Habib (Elsevier, 2016)Machining of difficult-to-cut materials like Ti6Al4V titanium alloy leads to significant flank wear on the cutting tool. In order to ensure the respect of final part specifications, flank wear has to be controlled. In ...
Mechanistic cutting force model including the stress state induced by the chip flow contribution for cylindrical turning on Ti6Al4V alloy with two different nose radii Communication avec acteDORLIN, Théo; FROMENTIN, Guillaume; COSTES, Jean-Philippe; KARAOUNI, Habib (2016)Force modelling is a major research topic in machining. Several approaches are used to face with the different needs. Mechanistic models appear to be an easier and rapid way for computing cutting forces; nevertheless they ...