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Error compensation of thin plate-shape part with prebending method in face milling

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Abstract

Low weight and good toughness thin plate parts are widely used in modern industry, but its flexibility seriously impacts the machinability. Plenty of studies focus on the influence of machine tool and cutting tool on the machining errors. However, few researches focus on compensating machining errors through the fixture. In order to improve the machining accuracy of thin plate-shape part in face milling, this paper presents a novel method for compensating the surface errors by prebending the workpiece during the milling process. First, a machining error prediction model using finite element method is formulated, which simplifies the contacts between the workpiece and fixture with spring constraints. Milling forces calculated by the micro-unit cutting force model are loaded on the error prediction model to predict the machining error. The error prediction results are substituted into the given formulas to obtain the prebending clamping forces and clamping positions. Consequently, the workpiece is prebent in terms of the calculated clamping forces and positions during the face milling operation to reduce the machining error. Finally, simulation and experimental tests are carried out to validate the correctness and efficiency of the proposed error compensation method. The experimental measured flatness results show that the flatness improves by approximately 30 percent through this error compensation method. The proposed method not only predicts the machining errors in face milling thin plate-shape parts but also reduces the machining errors by taking full advantage of the workpiece prebending caused by fixture, meanwhile, it provides a novel idea and theoretical basis for reducing milling errors and improving the milling accuracy.

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Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University, Ji’nan, 250061, China

    Wei Yi, Zhaoliang Jiang, Weixian Shao, Xiangcheng Han & Wenping Liu

  2. Engineering Training Center, Shandong University, Ji’nan, 250002, China

    Wei Yi

  3. Key Laboratory of High-efficiency and Clean Mechanical Manufacture at Shandong University, Ministry of Education, Ji’nan, 250061, China

    Zhaoliang Jiang & Wenping Liu

Authors
  1. Wei Yi
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  2. Zhaoliang Jiang
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  3. Weixian Shao
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  4. Xiangcheng Han
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  5. Wenping Liu
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Corresponding author

Correspondence to Zhaoliang Jiang.

Additional information

Supported by National Natural Science Foundation of China (Grant No. 51175304), and Shandong Provincial Science and Technology Development Plan of China (Grant No. 2013GHZ30305)

YI Wei, born in 1980, is currently a PhD candidate at School of Mechanical Engineering, Shandong University, China. His research interests include deformation mechanism of thin part induced by face milling and the compensation method for the deformation induced by face milling.

JIANG Zhaoliang, born in 1971, is currently a professor at Shandong University, China. He received his PhD degree from Shandong University, China, in 2004. His research interests include fixture optimization and advanced manufacturing technology.

SHAO Weixian, born in 1988, is currently a master candidate at School of Mechanical Engineering, Shandong University, China.

HAN Xiangcheng, born in 1988, is currently a master candidate at School of Mechanical Engineering, Shandong University, China.

LIU Wenping, born in 1973, is currently an associate professor at Shandong University, China. He received his PhD degree from Shandong University, China, in 2009.

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Yi, W., Jiang, Z., Shao, W. et al. Error compensation of thin plate-shape part with prebending method in face milling. Chin. J. Mech. Eng. 28, 88–95 (2015). https://doi.org/10.3901/CJME.2014.1120.171

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  • DOI: https://doi.org/10.3901/CJME.2014.1120.171

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