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A forward closed-loop virtual simulation system for milling process considering dynamics processing-machine interactions

Lookup NU author(s): Dr Dehong Huo

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This is the authors' accepted manuscript of an article that has been published in its final definitive form by Springer London, 2019.

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Abstract

© 2019, Springer-Verlag London Ltd., part of Springer Nature. In this paper, a closed-loop virtual simulation system has been developed to simulate the milling process considering the interactions between manufacturing processes and machine tool dynamics. The system consists of cutting force module, machining stability module, and surface generation module. The synchronous effects of the machining parameters, tool geometry parameters, and the dynamic performance of the machine tool system are considered in the model, and the instant machine dynamic motion error is compensated in the model as a feedback to correct the cutter trajectories. Instantaneous tool-workpiece contact status is used to calculate cutting force, and the peak-to-peak cutting force plot is used to predict the machining stability in time domain under different depths of cut and cutting speeds. The envelope curve of the cutting tool is used to reconstruct the machined surface texture. Moreover, to verify the feasibility of the proposed system, micro-milling experiments are conducted with results showing that the simulation system enables the effective prediction of micro-milling process such as the cutting forces and machined surface quality. It can be potentially applied in production on processing parameter optimization and surface topography prediction.


Publication metadata

Author(s): Chen W, Tong Z, Huo D, Zhong W, Jiang X

Publication type: Article

Publication status: Published

Journal: International Journal of Advanced Manufacturing Technology

Year: 2019

Volume: 104

Pages: 2317-2328

Online publication date: 03/07/2019

Acceptance date: 19/06/2019

Date deposited: 30/08/2019

ISSN (print): 0268-3768

ISSN (electronic): 1433-3015

Publisher: Springer London

URL: https://doi.org/10.1007/s00170-019-04057-7

DOI: 10.1007/s00170-019-04057-7


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