Research on deformation prediction and error compensation in precision turning of micro-shafts
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ORIGINAL ARTICLE
Research on deformation prediction and error compensation in precision turning of micro-shafts Chenxu Li 1 & Xibin Wang 2 & Pei Yan 2 & Zhongke Niu 3 & Shiqi Chen 1 & Li Jiao 2 Received: 15 December 2019 / Accepted: 9 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The precision turning process has attracted enormous interest in the standardized and mass production of micro-shafts because it produces more efficiency and lower cost compared with the electrical-discharge machining method and micro-machining method. However, there are many critical factors that influence the dimensional accuracy of micro-shafts, such as the error of workpiece deformation, cutting force, and tool setting error. In this paper, a novel error compensation method was proposed to improve the dimensional accuracy of micro-shafts manufactured with the conventional precision machine tool, based on the constant force cutting method and tool path planning. Firstly, a cutting force model was established considering the effect of the tool nose radius, and the finite element method was used to simulate the turning process and predict the workpiece deformation. Secondly, an error analysis model was created by taking tool setting error, workpiece deformation error, and multi-process cumulative error into account, and the optimized tool path and cutting parameters were obtained. Finally, a series of turning experiments were carried out to verify the error compensation strategy and the cutting force model. The results show that the dimensional error of the micro-shafts with a large length-diameter ratio (l = 5 mm, d = 0.4 mm) can be reduced by 90% by means of the proposed error compensation strategy. In addition, the maximum prediction error of cutting forces is less than 8.6%, and the effect of cutting parameters on cutting forces can be concluded as “feed rate > depth of cut > spindle speed.” Keywords Micro-shafts . Precision turning . Error compensation . Constant force cutting . Tool path planning . FEA method
1 Introduction Recently, the requirement for micro-scale components and products is increasing rapidly, particularly in the fields of electronics, communications, optics, avionics, medicine, automobiles, and so on [1–3]. Typical applications of such miniaturized products include micro-engines, micro-reactors, micro-heat exchangers, medical implants, drug delivery devices, and diagnostic devices [4, 5]. Various manufacturing techniques such as electrodischarge machining, ion beam machining, laser beam * Pei Yan [email protected] 1
School of Mechanical Engineering, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing 100081, People’s Republic of China
2
Key Laboratory of Fundamental Science for Advanced Machining, Beijing Institute of Technology, No. 5 Zhongguancun South Street, Haidian District, Beijing 100081, People’s Republic of China
3
Aerospace System Engineering Shanghai, Shanghai 201108, China
machining, and photolithography have been propose
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