Point-based tool representations for modeling complex tool shapes and runout for the simulation of process forces and chatter vibrations

Abstract

Geometric physically-based simulation systems can be used for analyzing and optimizing complex milling processes, for example in the automotive or aerospace industry, where the surface quality and process efficiency are limited due to chatter vibrations. Process simulations using tool models based on the constructive solid geometry (CSG) technique allow the analysis of process forces, tool deflections, and surface location errors resulting from five-axis machining operations. However, modeling complex tool shapes and effects like runout is difficult using CSG models due to the increasing complexity of the shape descriptions. Therefore, a point-based method for modeling the rotating tool considering its deflections is presented in this paper. With this method, tools with complex shapes and runout can be simulated in an efficient and flexible way. The new modeling approach is applied to exemplary milling processes and the simulation results are validated based on machining experiments.

Keywords

Modeling / Tool geometry / Milling

References

[1] Altintas Y, Kersting P, Biermann D, et al. Virtual process systems for part machining operations. CIRP Ann Manuf Technol, 2014, 63(2): 585-605.

[2] Denkena B, Böß V, Nespor D, et al. Simulation and evaluation of different process strategies in a 5-axis re-contouring process. Procedia CIRP, 2015, 35(31): 31-37.

[3] Wiederkehr P, Siebrecht T. Virtual machining: capabilities and challenges of process simulations in the aerospace industry. Procedia Manuf, 2016, 6: 80-87.

[4] Arrazola PJ, Özel T, Umbrello D, et al. Recent advances in modelling of metal machining processes. CIRP Ann Manuf Technol, 2013, 62: 695-718.

[5] Munoa J, Beudaert X, Dombovari Z, et al. Chatter suppression techniques in metal cutting. CIRP Ann Manuf Technol, 2016, 65(2): 785-808.

[6] Biermann D, Iovkov I. Modelling, simulation and compensation of thermal effects for complex machining processes. Prod Eng, 2015, 9(4): 1-3.

[7] Odendahl S, Kersting P. Higher efficiency modeling of surface location errors by using a multi-scale milling simulation. Procedia CIRP, 2013, 9: 18-22.

[8] Denkena B, Grove T, Ermisch A, et al. New simulation based method for the design of cut-off grinding segments for circular saws, 2014, Antalya, Turkey: Global Stone Congress 146-156.

[9] Hense R, Baumann J, Siebrecht T et al (2015) Simulation of an active fixture system for preventing workpiece vibrations during milling. In: Proceedings of the 4th international conference on virtual machining process technology, 2015

[10] Martelotti ME. An analysis of milling process. Trans ASME, 1941, 122: 3-11.

[11] Kienzle O. Die Bestimmung von Kräften und Leistungen an spanenden Werkzeugen und Werkzeugmaschinen. Z Ver Dtsch Ing, 1952, 94: 299-305.

[12] Koenigsberger R, Sabberwal AJP. An investigation into the cutting force pulsations during milling operations. Int J Mach Tool Des Res, 1961, 1: 15-33.

[13] Kline WA, DeVor RE, Lindberg JR. The prediction of cutting forces in the end milling with application to cornering cuts. Int J Mach Tool Des Res, 1982, 22: 7-22.

[14] Budak E, Altintas Y, Armarego EJA. Prediction of milling force coefficients from orthogonal cutting data. Trans ASME, 1996, 118: 216-224.

[15] Kline WA, DeVor RE. The effect of runout on cutting geometry and forces in end milling. Int J Mach Tool Des Res, 1983, 2–3: 123-140.

[16] Weinert K, Surmann T, Enk D, Webber O. The effect of runout on the milling tool vibration and surface quality. Prod Eng Res Devel, 2007, 2: 265-270.

[17] Merdol DS, Altintas Y. Mechanics and dynamics of serrated cylindrical and tapered end mills. J Manuf Sci Eng, 2004, 126: 317-326.

[18] Budak E. An analytical design method for milling cutters with nonconstant pitch to increase stability: part 2. J Manuf Sci Eng, 2003, 125: 35-38.

[19] Tunç LT, Özkirimli Ö, Budak E. Generalized cutting force model in multi-axis milling using a new engagement boundary determination approach. Int J Adv Manuf Technol, 2015, 77: 341-355.

[20] Fu Z, Yang W, Wang X, Leopold J. Analytical simulation of milling: influence of tool design on cutting forces. Procedia CIRP, 2015, 31: 258-263.

[21] Engin S, Altıntaş Y. Mechanics and dynamics of general milling cutters, part I—helical end mills. Int J Mach Tools Manuf, 2001, 41: 2213-2231.

[22] Foley J, Feiner S, Hughes J. Introduction to computer graphics, 1993, Reading, MA: Addison-Wesley 559.

[23] Weinert K, Surmann T. Geometric simulation of the milling process for free formed surfaces, simulation aided offline process design and optimization in manufacturing sculptured surfaces. Witten, 2003, 27: 21-30.

[24] Surmann T, Biermann D, Kehl G (2008) Oscillator model of machine tools for the simulation of self excited vibrations in machining processes. In: Proceedings of the 1st international conference on process machine interactions, Hannover, Germany, pp 23–29