Error compensation of thin plate-shape part with prebending method in face milling

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• 作者：Wei Yi (1) (2)
  Zhaoliang Jiang (1) (3)
  Weixian Shao (1)
  Xiangcheng Han (1)
  Wenping Liu (1) (3)
  
  1. School of Mechanical Engineering ; Shandong University ; Ji鈥檔an ; 250061 ; China
  2. Engineering Training Center ; Shandong University ; Ji鈥檔an ; 250002 ; China
  3. Key Laboratory of High-efficiency and Clean Mechanical Manufacture at Shandong University ; Ministry of Education ; Ji鈥檔an ; 250061 ; China
  
• 关键词：face milling ; error prediction ; prebending ; error compensation ; fixture
• 刊名：Chinese Journal of Mechanical Engineering
• 出版年：2015
• 出版时间：January 2015
• 年：2015
• 卷：28
• 期：1
• 页码：88-95
• 全文大小：733 KB
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• 刊物主题：Mechanical Engineering; Theoretical and Applied Mechanics; Manufacturing, Machines, Tools; Engineering Thermodynamics, Heat and Mass Transfer; Power Electronics, Electrical Machines and Networks; Electronics and Microelectronics, Instrumentation;
• 出版者：Springer Berlin Heidelberg
• ISSN：2192-8258

文摘

Low weight and good toughness thin plate parts are widely used in modern industry, but its flexibility seriously impacts the machinability. Plenty of studies focus on the influence of machine tool and cutting tool on the machining errors. However, few researches focus on compensating machining errors through the fixture. In order to improve the machining accuracy of thin plate-shape part in face milling, this paper presents a novel method for compensating the surface errors by prebending the workpiece during the milling process. First, a machining error prediction model using finite element method is formulated, which simplifies the contacts between the workpiece and fixture with spring constraints. Milling forces calculated by the micro-unit cutting force model are loaded on the error prediction model to predict the machining error. The error prediction results are substituted into the given formulas to obtain the prebending clamping forces and clamping positions. Consequently, the workpiece is prebent in terms of the calculated clamping forces and positions during the face milling operation to reduce the machining error. Finally, simulation and experimental tests are carried out to validate the correctness and efficiency of the proposed error compensation method. The experimental measured flatness results show that the flatness improves by approximately 30 percent through this error compensation method. The proposed method not only predicts the machining errors in face milling thin plate-shape parts but also reduces the machining errors by taking full advantage of the workpiece prebending caused by fixture, meanwhile, it provides a novel idea and theoretical basis for reducing milling errors and improving the milling accuracy.