Material removal simulation of peripheral milling of thin wall low-rigidity structures using FEA

Authors:
Svetan Ratchev;Stan Nikov;Idir Moualek
Affiliations:
School of Mechanical, Materials, Manufacturing, Engineering and Management, Nottingham University, University Park, Nottingham NG7 2RD, UK;School of Mechanical, Materials, Manufacturing, Engineering and Management, Nottingham University, University Park, Nottingham NG7 2RD, UK;School of Mechanical, Materials, Manufacturing, Engineering and Management, Nottingham University, University Park, Nottingham NG7 2RD, UK
Venue:
Advances in Engineering Software
Year:
2004

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Abstract

The paper reports on a new methodology for simulation of the material removal process that takes into account the deflection of the part during machining. A finite element part model is used as an input to the simulation. The algorithm aims to iteratively identify the intersection between the tool volume and the deflected part taking into account the applied cutting forces. A new voxel-transformation model and algorithm have been developed to allow accurate representation of cutting through the part voxels intersected by the tool volume. A look-up table describing all possible voxel-cutting schemes has been developed and validated to facilitate the material removal simulation. The methodology has been implemented as a software package that allows integration with mainstream commercial finite element analysis and CAD packages.