A time-varying geometry modeling method for parts with deformation during machining process |
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| Affiliation: | 1. National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China;2. Hong Kong University of Science and Technology, Clear Water Bay, HK, China;1. Department of Micro Engineering, Kyoto University, Katsura Nishikyo-ku, Kyoto, 615-8540, Japan;2. Department of Mechanical Systems Engineering, Hiroshima University, Kagamiyama, Higashi-Hiroshima, 739-8511, Japan;1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China;2. Faculty of Engineering and Science, University of Greenwich, Chatham Maritime, Kent ME4 4TB, UK;3. Department of Mechanical Engineering, University of Bath, Bath BA2 7AY, UK;1. State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, PR China;2. Manufacturing Automation Laboratory, Department of Mechanical Engineering, The University of British Columbia, Vancouver, BC, V6T 1Z4, Canada;1. School of Automotive Engineering, Dalian University of Technology, Dalian 116024, China;2. School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China;1. State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China;2. Beijing Key Lab of Precision/Ultra-precision Manufacturing Equipment and Control, Beijing 100084, China |
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| Abstract: | Deformation due to residual stress is a significant issue during the machining of thin-walled parts with low rigidity. If there are multiple processes with deformation during machining, some process suitability issues will appear. On this occasion, the actual geometric state of the deformed workpiece is needed for process adjustment. However, it is still a challenge to obtain the complete geometry information of deformed workpiece accurately and efficiently. In order to address this issue, a time-varying geometry modeling method, combining cutting simulation and in-process measurement, is proposed in this paper. The deformed workpiece model can be reconstructed via transforming the deformed workpiece with only a small amount of the measurement points by superimposing material removal and workpiece deformation simulation according to a time sequence, which takes advantage of the proposed Curved Surface Mapping based Geometric Representation Model (CSMGRM). Machining experiment of a typical structural part has shown that the deformed geometry model of the whole workpiece can be reconstructed within the error of 0.05mm, which is less than one tenth of the finish machining allowance in general cases, and it is sufficient to meet the accuracy requirements for interference or overcut/undercut analysis and process adjustment. |
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| Keywords: | Structural parts Deformation representation Cutting simulation Curved surface mapping Time-varying geometry modeling |
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