FEM-Based Simulation for Workpiece Deformation in Thin-Wall Milling
Jun Wang, Soichi Ibaraki, Atsushi Matsubara, Kosuke Shida, Takayuki Yamada
Abstract
This paper focuses on the deformation of a thin wall
during the milling process. Cutting experiments were
performed to investigate the influence of the workpiece
thickness on its deformation and the cutting force. An
FEM-based model was developed to simulate the deformation
of a thin-wall workpiece during the milling
process. With a tool’s rotation, the cutting force is distributed
along the helical cutting edge, and the workpiece
deformation can be calculated for a given time
interval. The simulated results were compared with
those of a simplermodel where a constant cutting force
is uniformly distributed along an oblique line representing
the material removal by a cylindrical tool. Finally,
the application of these results to the design of
ribs for thin-wall parts during machining was considered.
Keywords: deformation, thin wall, milling, rib
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