FEM-based optimization approach to machining strategy for thin-walled parts made of hard and brittle materials
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ORIGINAL ARTICLE
FEM-based optimization approach to machining strategy for thin-walled parts made of hard and brittle materials Zhiqiang Liu 1 & Renke Kang 1 & Haijun Liu 2 & Zhigang Dong 1 & Yan Bao 1 & Shang Gao 1 & Xianglong Zhu 1 Received: 3 December 2019 / Accepted: 17 August 2020 / Published online: 24 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Thin-walled parts are widely used in the aerospace, automotive, and medical industries. High machining efficiency is desired as much of the material needs to be removed. The aggressive machining strategies are often applied but tend to cause poor surface finish, inadequate machining tolerance, and even fracture of workpiece. Thus, it is of vital importance to adopt reasonable machining strategy and choose accurate machining parameters considering of both the machining efficiency and quality. In this paper, an optimization approach to enhance machining efficiency for thin-walled parts made of hard and brittle material without compromising machining quality was proposed. The core idea of the proposed approach is to minimize the maximum stress of the thin-walled part during machining by optimizing the workpiece shape based on finite element method (FEM). The stiffness of the thin-walled parts during machining retains high while the machining induced deformation is small. The optimization approach was experimentally validated on K9 glass, and the maximum deformation of the thin-walled part for the optimal machining strategy decreases significantly compared with that of traditional machining strategy and the total machining time is reduced by 44%. Keywords K9 . Thin-walled part . Machining strategy optimization . Finite element method
1 Introduction Thin-walled parts are widely used in the aerospace, automotive, and medical industries due to their homogeneity and excellent strength-to-weight-ratio. Thin-walled parts are obtained from a raw block of material, and up to 95% of the weight of the initial block needs to be removed. Therefore, the aggressive machining strategy is often applied in machining of thin-walled parts to increase the material removal rate as much as possible. However, the inherent low stiffness of the thin-walled parts leads to many machining challenges, such as poor surface finish, inadequate machining tolerance, and even fracture of the workpieces.
* Zhigang Dong [email protected] 1
Key Laboratory for Precision and Non-Traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian 116024, China
2
School of Mechanical Engineering, Hefei University of Technology, Hefei 230009, China
To address these problems, some researchers studied the prediction, reduction, and prevention of machining chattering [1, 2] based on the stability lobe [3]. The others investigated the machining deformation prediction, reduction, and error compensation method. Liu et al. [4] proposed an error prediction method for the five-axis flank milling of a thin-walled part considering the effect of the ra
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