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

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 o...

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Bibliographic Details
Published in:Advances in manufacturing 2018-09, Vol.6 (3), p.301-307
Main Authors: Wiederkehr, P., Siebrecht, T., Baumann, J., Biermann, D.
Format: Article
Language:English
Subjects:
Aerospace industry
Automobile industry
Automotive engineering
Chatter
Complexity
Computer simulation
Constructive solid geometry
Control
Engineering
Five axis
Machines
Manufacturing
Mechatronics
Milling (machining)
Modelling
Nanotechnology and Microengineering
Processes
Robotics
Simulation
Surface properties
Vibration
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Summary: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.
ISSN:2095-3127
2195-3597
DOI:10.1007/s40436-018-0219-8