Numerical Simulation And Analysis For Milling Process Of Thin-walled Workpiece

In order to meet the challenges for rapid developments of advanced manufacturing technologies, numerical finite element methods are systematically studied to simulate the milling process. Efforts are focused on the milling force modeling and the prediction of form error caused by milling deformation.The work is organized as follows: firstly, the basic theory of metal cutting is presented. In this context, cutting force modeling associated with peripheral and face milling is investigated. Secondly, finite element method is introduced. Its applicability in cutting process is illustrated by a 2-D turning problem. The main work is focused on the application of super-element(SE) technique in milling simulation. This technique has the great advantage in computing efficiency when large-scale problems are solved since only the machining surfaces need to calculate.Two typical examples are given to demonstrate the numerical simulation results of peripheral and face milling process. Form error distributes are illustrated to understand the machining quality and a comparison of computing time is given between the direct finite element method and the SE formulation.This research constitutes a fundamental work in potential application of simulation methods to aeronautical manufacturing engineering.