Prediction of machining accuracy based on geometric error estimation of tool rotation profile in five-axis multi-layer flank milling process

Hangzhuo Yu, Lei Jiang*, Jindong Wang, Shengfeng Qin, Guofu Ding

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

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Abstract

In five-axis multi-layer flank milling process, the geometric error of tool rotation profile caused by radial dimension error and setup error has great influence on the machining accuracy. In this work, a new comprehensive error prediction model considering the inter-layer interference caused by tool rotation profile error is established, which incorporates a pre-existing prediction model dealing with a variety of errors such as geometric errors of machine tool, workpiece locating errors, and spindle thermal deflection errors. First, a series of tool contact points on the tool swept surface in each single layer without overlapping with others are calculated. Second, the position of the tool contact points on the overlapped layers is updated based on the detection and calculation of inter-layer interferences. Third, all evaluated tool contact points on the final machined surface are available for completing the accuracy prediction of the machined surface. A machining experiment has been carried out to validate this prediction model and the results show the model is effective.

Original languageEnglish
Pages (from-to)2160-2177
Number of pages18
JournalProceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science
Volume234
Issue number11
Early online date10 Feb 2020
DOIs
Publication statusPublished - 1 Jun 2020

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