Voxel Based End-milling Simulation Considering Elastic Deflection of Tool System

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  • 工具系の弾性変形を考慮したボクセルモデルによるエンドミル加工シミュレーション

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Abstract

<p>In order to improve machining efficiency, it is required to recognize machining status and optimize cutting conditions. This study develops a newly cutting simulator for end-milling operation, which considers the elastic deflection of tool system. This simulator is based on an instantaneous rigid force model. The uncut chip thickness, which is required to estimate cutting force, is calculated under the consideration of the elastic deflection of the tool system, which corresponds to tool and tool holder deflections caused by cutting force. The newly developed end-milling simulator represents work material by voxel model and calculates the uncut chip thickness from the removed voxels, which are penetrated by tool cutting edges. In our previous study, the uncut chip thickness is calculated from voxels removed by each minute tool rotational angle, and the instantaneous cutting force in a minute time interval can be estimated. Therefore, this study proposes a method to consider the elastic deflection of the tool system caused by the estimated instantaneous cutting force. This study considers the elastic deflection of the tool system, which consists of the tool deflection, the displacement between the tool and the tool holder parallel to the tool axis, the displacement between the tool holder and the spindle parallel to the spindle axis, and the rotational displacement at the tool holding part. The actual uncut chip thickness affected by the elastic deflection of the tool system has to be calculated to estimate the actual cutting force for each minute time. In order to validate the effectiveness of the proposed algorithm, the experimental 3-axis milling operations were conducted. It was confirmed that the predicted cross-sectional shape of the machined surface had good agreement with the measured one.</p>

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