Prediction of Surface Location Error by Time Finite Element Analysis and Euler Integration

Published

January 1, 2002

Author(s)

P V. Bayly, Johannes A. Soons, Tony L. Schmitz, Brian S. Dutterer

Abstract

This paper presents experimental and simulated results for surface location errors in milling. These errors occur due to the inherent flexibility in the workpiece/tool/spindle/machine system and are determined by the instantaneous tool deflection as it leaves the machined surface, i.e., entering the cut in up milling or exiting the cut in down milling, which is determined by the relationship between the system natural frequency and forcing frequency, or spindle speed. Two different simulation algorithms were implemented including Bayly?s TFEA method and a modification of Tlusty?s Euler integration scheme. Good agreement between the two methods was recorded. Cutting tests were completed for 1) slot machining using both two and three flute end mills to show the stronger influence of spindle speed on slot width for three flute tools and slot location for two flute tools, 2) low radial immersion machining in both up and down milling cutting directions to demonstrate the large changes in part dimensions as a function of spindle speed, and 3) thin rib production to show a practical example of the importance of surface location errors.

Proceedings Title

Proceedings of the Seventh Annual Meeting, American Society for Precision Engineering

Volume

27

Conference Dates

October 20-25, 2002

Conference Location

St. Louis, MO, USA

Conference Title

Seventh Annual Meeting, American Society for Precision Engineering

Pub Type

Conferences

Keywords

dynamics, milling, surface location error

Citation

Bayly, P. , Soons, J. , Schmitz, T. and Dutterer, B. (2002), Prediction of Surface Location Error by Time Finite Element Analysis and Euler Integration, Proceedings of the Seventh Annual Meeting, American Society for Precision Engineering, St. Louis, MO, USA (Accessed April 20, 2024)