Skip to main content
SpringerLink
Log in

Point-based tool representations for modeling complex tool shapes and runout for the simulation of process forces and chatter vibrations

  • Published:
Advances in Manufacturing Aims and scope Submit manuscript

Abstract

Geometric physically-based simulation systems can be used for analyzing and optimizing complex milling processes, for example in the automotive or aerospace industry, where the surface quality and process efficiency are limited due to chatter vibrations. Process simulations using tool models based on the constructive solid geometry (CSG) technique allow the analysis of process forces, tool deflections, and surface location errors resulting from five-axis machining operations. However, modeling complex tool shapes and effects like runout is difficult using CSG models due to the increasing complexity of the shape descriptions. Therefore, a point-based method for modeling the rotating tool considering its deflections is presented in this paper. With this method, tools with complex shapes and runout can be simulated in an efficient and flexible way. The new modeling approach is applied to exemplary milling processes and the simulation results are validated based on machining experiments.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8

Similar content being viewed by others

References

  1. Altintas Y, Kersting P, Biermann D et al (2014) Virtual process systems for part machining operations. CIRP Ann Manuf Technol 63(2):585–605

    Article  Google Scholar 

  2. Denkena B, Böß V, Nespor D et al (2015) Simulation and evaluation of different process strategies in a 5-axis re-contouring process. Procedia CIRP 35(31):31–37

    Article  Google Scholar 

  3. Wiederkehr P, Siebrecht T (2016) Virtual machining: capabilities and challenges of process simulations in the aerospace industry. Procedia Manuf 6:80–87

    Article  Google Scholar 

  4. Arrazola PJ, Özel T, Umbrello D et al (2013) Recent advances in modelling of metal machining processes. CIRP Ann Manuf Technol 62:695–718

    Article  Google Scholar 

  5. Munoa J, Beudaert X, Dombovari Z et al (2016) Chatter suppression techniques in metal cutting. CIRP Ann Manuf Technol 65(2):785–808

    Article  Google Scholar 

  6. Biermann D, Iovkov I (2015) Modelling, simulation and compensation of thermal effects for complex machining processes. Prod Eng 9(4):1–3

    Google Scholar 

  7. Odendahl S, Kersting P (2013) Higher efficiency modeling of surface location errors by using a multi-scale milling simulation. Procedia CIRP 9:18–22

    Article  Google Scholar 

  8. Denkena B, Grove T, Ermisch A et al (2014) New simulation based method for the design of cut-off grinding segments for circular saws. Global Stone Congress, Antalya, Turkey, pp 146–156

    Google Scholar 

  9. Hense R, Baumann J, Siebrecht T et al (2015) Simulation of an active fixture system for preventing workpiece vibrations during milling. In: Proceedings of the 4th international conference on virtual machining process technology, 2015

  10. Martelotti ME (1941) An analysis of milling process. Trans ASME 122:3–11

    Google Scholar 

  11. Kienzle O (1952) Die Bestimmung von Kräften und Leistungen an spanenden Werkzeugen und Werkzeugmaschinen. Z Ver Dtsch Ing 94:299–305

    Google Scholar 

  12. Koenigsberger R, Sabberwal AJP (1961) An investigation into the cutting force pulsations during milling operations. Int J Mach Tool Des Res 1:15–33

    Article  Google Scholar 

  13. Kline WA, DeVor RE, Lindberg JR (1982) The prediction of cutting forces in the end milling with application to cornering cuts. Int J Mach Tool Des Res 22:7–22

    Article  Google Scholar 

  14. Budak E, Altintas Y, Armarego EJA (1996) Prediction of milling force coefficients from orthogonal cutting data. Trans ASME 118:216–224

    Google Scholar 

  15. Kline WA, DeVor RE (1983) The effect of runout on cutting geometry and forces in end milling. Int J Mach Tool Des Res 2–3:123–140

    Article  Google Scholar 

  16. Weinert K, Surmann T, Enk D et al (2007) The effect of runout on the milling tool vibration and surface quality. Prod Eng Res Devel 2:265–270

    Article  Google Scholar 

  17. Merdol DS, Altintas Y (2004) Mechanics and dynamics of serrated cylindrical and tapered end mills. J Manuf Sci Eng 126:317–326

    Article  Google Scholar 

  18. Budak E (2003) An analytical design method for milling cutters with nonconstant pitch to increase stability: part 2. J Manuf Sci Eng 125:35–38

    Article  Google Scholar 

  19. Tunç LT, Özkirimli Ö, Budak E (2015) Generalized cutting force model in multi-axis milling using a new engagement boundary determination approach. Int J Adv Manuf Technol 77:341–355

    Article  Google Scholar 

  20. Fu Z, Yang W, Wang X et al (2015) Analytical simulation of milling: influence of tool design on cutting forces. Procedia CIRP 31:258–263

    Article  Google Scholar 

  21. Engin S, Altıntaş Y (2001) Mechanics and dynamics of general milling cutters, part I—helical end mills. Int J Mach Tools Manuf 41:2213–2231

    Article  Google Scholar 

  22. Foley J, Feiner S, Hughes J (1993) Introduction to computer graphics. Addison-Wesley, Reading, MA, p 559

    MATH  Google Scholar 

  23. Weinert K, Surmann T (2003) Geometric simulation of the milling process for free formed surfaces, simulation aided offline process design and optimization in manufacturing sculptured surfaces. Witten 27:21–30

    Google Scholar 

  24. Surmann T, Biermann D, Kehl G (2008) Oscillator model of machine tools for the simulation of self excited vibrations in machining processes. In: Proceedings of the 1st international conference on process machine interactions, Hannover, Germany, pp 23–29

Download references

Author information

Authors and Affiliations

  1. Institute of Machining Technology, TU Dortmund University, Dortmund, Germany

    P. Wiederkehr, T. Siebrecht, J. Baumann & D. Biermann

  2. Virtual Machining, Department of Computer Science, TU Dortmund University, Dortmund, Germany

    P. Wiederkehr & T. Siebrecht

Authors
  1. P. Wiederkehr
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. T. Siebrecht
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. J. Baumann
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. D. Biermann
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to T. Siebrecht.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wiederkehr, P., Siebrecht, T., Baumann, J. et al. Point-based tool representations for modeling complex tool shapes and runout for the simulation of process forces and chatter vibrations. Adv. Manuf. 6, 301–307 (2018). https://doi.org/10.1007/s40436-018-0219-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40436-018-0219-8

Keywords

Search

Navigation