Advertisement

Simulation of Thin-Walled Parts End Milling with Fluid Jet Support

  • Serhii Kononenko
  • Sergey Dobrotvorskiy
  • Yevheniia BasovaEmail author
  • Ludmila Dobrovolska
  • Vitalii Yepifanov
Conference paper
  • 101 Downloads
Part of the Lecture Notes in Mechanical Engineering book series (LNME)

Abstract

One of the biggest barriers in the formation of surfaces of the thin-walled parts is the difficulties of prediction and prevention of deflections. The research is focused on the use of fluid jet support in processing as the technique to increase material cutting stability. The analysis of existing methods of deviations prevention is made. A preliminary number of simulations are proposed to define dynamic cutting parameters, apply it to the fluid jet simulation, and investigate the influence on the frequency part structure characteristics. The simulation results are allowed to trace the change in the natural frequency of the part and part with jet support. The potential fluid flow speed is established. The degree of the stress caused by directional fluid jet force is calculated. The technique is novel and useful in the sense that it is supported by fluid flow jet that can theoretically be organized on the existing equipment basis. The solution does not significantly affect the characteristics of the equipment structure while saving dimensional parameters. Matching between nozzle diameters and efficiency of fluid jet support is presented. Considerable oscillation amplitude reduction of the thin-walled part was observed using the proposed solution.

Keywords

Thin-walled parts Fluid jet support High-speed milling SPH-particles Undesirable deflections Oscillation amplitude 

References

  1. 1.
    Dobrotvorskiy, S., Basova, Y., Kononenko, S., Dobrovolska, L., Ivanova, M.: Numerical deflections analysis of variable low stiffness of thin-walled parts during milling. In: Ivanov, V., et al. (eds.) Advances in Design, Simulation and Manufacturing II, DSMIE-2019. LNME, pp. 43–53. Springer, Cham (2020)CrossRefGoogle Scholar
  2. 2.
    Kononenko, S., Dobrotvorskiy, S., Basova, Y., Gasanov, M., Dobrovolska, L.: Deflections and frequency analysis in the milling of thin-walled parts with variable low stiffness. Acta Polytech. 59, 283–291 (2019)CrossRefGoogle Scholar
  3. 3.
    Bashistakumar, M., Pushkal, B.: Finite element analysis of orthogonal cutting forces in machining AISI 1020 steel using a carbide tip tool. J. Eng. Sci. 4(1), A11–A15 (2017)Google Scholar
  4. 4.
    Kolluru, K., Axinte, D.: Novel ancillary device for minimising machining vibrations in thin wall assemblies. Int. J. Mach. Tools Manuf. 85, 79–86 (2014)CrossRefGoogle Scholar
  5. 5.
    Ivanov, V., Mital, D., Karpus, V., Dehtiarov, I., Zajac, J., Pavlenko, I., Hatala, M.: Numerical simulation of the system “fixture–workpiece” for lever machining. Int. J. Adv. Manuf. Technol. 91(1–4), 79–90 (2017).  https://doi.org/10.1007/s00170-016-9701-2CrossRefGoogle Scholar
  6. 6.
    Ivanov, V., Dehtiarov, I., Denysenko, Y., Malovana, N., Martynova, N.: Experimental diagnostic research of fixture. Diagnostyka 19(3), 3–9 (2018).  https://doi.org/10.29354/diag/92293CrossRefGoogle Scholar
  7. 7.
    Feng, J., Wan, M., Gao, T.-Q., Zhang, W.-H.: Mechanism of process damping in milling of thin-walled workpiece. Int. J. Mach. Tools Manuf. 134, 1–19 (2018)CrossRefGoogle Scholar
  8. 8.
    Liu, C., Sun, J., Li, Y., Li, J.: Investigation on the milling performance of titanium alloy thin-walled part with air jet assistance. Int. J. Adv. Manuf. Technol. 95, 2865–2874 (2017)CrossRefGoogle Scholar
  9. 9.
    Vukman, J., Lukić, D., Milošević, M., Borojević, S., Antić, A., Đurđev, M.: Fundamentals of the optimization of machining process planning for the thin-walled aluminium parts. J. Prod. Eng. 19(2), 53–56 (2016)Google Scholar
  10. 10.
    Schulze, V., Arrazola, P., Zanger, F., Osterried, J.: Simulation of distortion due to machining of thin-walled components. Proc. CIRP 8, 45–50 (2013)CrossRefGoogle Scholar
  11. 11.
    Fei, J., Lin, B., Xiao, J., Ding, M., Yan, S., Zhang, X., Zhang, J.: Investigation of moving fixture on deformation suppression during milling process of thin-walled structures. J. Manuf. Process. 32, 403–411 (2018)CrossRefGoogle Scholar
  12. 12.
    Diez, E., Perez, H., Marquez, J., Vizan, A.: Feasibility study of in-process compensation of deformations in flexible milling. Int. J. Mach. Tools Manuf. 94, 1–14 (2015)CrossRefGoogle Scholar
  13. 13.
    Wang, M.-H., Sun, Y.: Error prediction and compensation based on interference-free tool paths in blade milling. Int. J. Adv. Manuf. Technol. 71, 1309–1318 (2014)CrossRefGoogle Scholar
  14. 14.
    Ratchev, S., Govender, E., Nikov, S., Phuah, K., Tsiklos, G.: Force and deflection modelling in milling of low-rigidity complex parts. J. Mater. Process. Technol. 143–144, 796–801 (2003)CrossRefGoogle Scholar
  15. 15.
    Wan, X.-J., Hua, L., Wang, X.-F., Peng, Q.-Z., Qin, X.: An error control approach to tool path adjustment conforming to the deformation of thin-walled workpiece. Int. J. Mach. Tools Manuf. 51, 221–229 (2011)CrossRefGoogle Scholar
  16. 16.
    Ramanaiah, B.V., Manikanta, B., Ravi Sankar, M., Malhotra, M., Gajrani, K.: Experimental study of deflection and surface roughness in thin wall machining of aluminum alloy. Mater. Today Proc. 5, 3745–3754 (2018)CrossRefGoogle Scholar
  17. 17.
    Padmanaban, K.P., Prabhaharan, G.: Dynamic analysis on optimal placement of fixturing elements using evolutionary techniques. Int. J. Prod. Res. 46, 4177–4214 (2008)CrossRefGoogle Scholar
  18. 18.
    Vasundara, M., Padmanaban, K.P.: Recent developments on machining fixture layout design, analysis, and optimization using finite element method and evolutionary techniques. Int. J. Adv. Manuf. Technol. 70, 79–96 (2013)CrossRefGoogle Scholar
  19. 19.
    Ivanov, V.: Process-oriented approach to fixture design. In: Ivanov, V., et al. (eds.) Advances in Design, Simulation and Manufacturing, DSMIE 2018. LNME, pp. 42–50. Springer, Cham (2019)CrossRefGoogle Scholar
  20. 20.
    Wan, X.-J., Zhang, Y.: A novel approach to fixture layout optimization on maximizing dynamic machinability. Int. J. Mach. Tools Manuf. 70, 32–44 (2013)CrossRefGoogle Scholar
  21. 21.
    Ivanov, V., Dehtiarov, I., Pavlenko, I., Kosov, I., Kosov, M.: Technology for complex parts machining in multiproduct manufacturing. Manage. Prod. Eng. Rev. 10(2), 25–36 (2019)Google Scholar
  22. 22.
    Usatyi, O., Avdieieva, O., Maksiuta, D., Tuan, P.: Experience in applying DOE methods to create formal macromodels of characteristics of elements of the flowing part of steam turbines. In: 17th Conference of Power System Engineering, Thermodynamics and Fluid Mechanics, AIP Conference Proceedings, Pilsen, Czech Republic, vol. 2047, no. 1, p. 020025 (2018)Google Scholar

Copyright information

© The Editor(s) (if applicable) and The Author(s), under exclusive license to Springer Nature Switzerland AG 2020

Authors and Affiliations

  1. 1.National Technical University “Kharkiv Polytechnic Institute”KharkivUkraine

Personalised recommendations