Error Compensation Methods Of Cutting Deformation For Thin-walled Parts With The Fillet-end Mill Cutter

NC machine tool as a high-tech product has been increasingly applied in these industries, such as Aeronautics & Astronautics, energy, machinery,and so on. Along with the high speed, intelligence, and constantly improved monitoring function of the machine tool, the machining efficiency and machining precision of the machine tool was increased greatly. Its superior outline machining accuracy for the complicated surface and the characteristic of five axis machining, make NC machine tools become the important equipment in the development of national economy. In order to improve the outline machining precision and machining quality for the complicated surface in the process of NC machining, the sources of causing surface machining error should be analyzed, the machining error should be monitored, and eventually the error should be compensated by taking corresponding compensation measures to offset and homogenization machining error.For thin-walled parts, the elastic deformation caused by the cutting force has become an important factor affecting the machining accuracy of the surface of work piece. In this paper, the prediction of machining error caused by the cutting force and the error compensation technology for thin-walled parts with the fillet-end mill cutter are studied, and two error compensation methods of cutting deformation based on the cutting force model are proposed. The contents of the method one are briefed as follows:(1) Get the cutting force in a given cutting depth, analyze and predict the machining error of each cutter locations with finite element software(ABAQUS).(2) Set up the model of the relationship between the cutting force and deformation error according to the cutting force and deformation, establish the iterative formula of the cutting force and error compensation on the basis of considering the coupling of the compensation and deformation error, and get the final compensation by modifying the cutting depth.The contents of the method two are briefed as follows:(1) Simulate the three milling process with the finite element(ABAQUS)software, set up the relationship model of the axial cutting depth, radial cutting depth and lead angle by analyzing and predicting the change of the surface of the parts before and after elastic deformation.(2) Set up iterative calculation formula of the elastic deformation by considering the feedback between the axial cutting depth, radial cutting depth, lead angle and the cutting force.Eventually, the error compensation methods of cutting deformation for thin-walled parts based on the cutting force model are tested by simulation software(ABAQUS). And the results are compared and analyzed with the results of the single error compensation method. It proves that the methods are proposed in this paper are effective and valid.