Title: Accuracy analysis of tool deflection error modelling in prediction of milled surfaces by a virtual machining system

Authors: Mohsen Soori; Behrooz Arezoo; Mohsen Habibi

Addresses: CAD/CAPP/CAM Research Center, Department of Mechanical Engineering, Amirkabir University of Technology (Tehran Polytechnic), 424 Hafez Avenue, Tehran 15875-4413, Iran ' CAD/CAPP/CAM Research Center, Department of Mechanical Engineering, Amirkabir University of Technology (Tehran Polytechnic), 424 Hafez Avenue, Tehran 15875-4413, Iran ' CAD/CAPP/CAM Research Center, Department of Mechanical Engineering, Amirkabir University of Technology (Tehran Polytechnic), 424 Hafez Avenue, Tehran 15875-4413, Iran

Abstract: Accuracy of produced parts in machining process is influenced by many errors such as tool deflection as well as geometrical deviations of machine tool structure. To increase accuracy and productivity in part manufacturing, the errors are modelled by using mathematical concepts. This paper presents an application for the virtual machining systems to analyse accuracy in modelling of tool deflection error. A virtual machining system is used to create actual parts in virtual environments. Then, a comparison for different methods of tool deflection error such as cantilever beam model of the cutting tool, Finite Element Method (FEM) of the cutting tool and workpiece and geometrical model of the cutting tool effects on the workpiece is presented to show accuracy and reliability of the methods in prediction of milled surfaces. So, capabilities and difficulties of the methods in the error modelling are presented to increase accuracy and efficiency in part manufacturing.

Keywords: virtual machining; tool deflection error; accuracy of error modelling; FEM; finite element method; three-axis CNC.

DOI: 10.1504/IJCAT.2017.086015

International Journal of Computer Applications in Technology, 2017 Vol.55 No.4, pp.308 - 321

Available online: 04 Aug 2017 *

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