An Analysis of Workpiece Thermostructural Distortions in Peripheral Milling by Finite Element Method

Sarang R. Garud | MS | 2002

Abstract:

Being one of the most versatile machining processes, end milling has always been the focus of significant research. Research in the past has dealt with predicting the cutting forces, workpiece deflections, and the effect of various machining parameters on the dimensional accuracy of the workpiece. Considering the magnitude of research work already done in the field of prediction of cutting forces, it is surprising that the literature review indicates comparatively little work available regarding the analysis of thermal effects of machining heat on the dimensional accuracy of the workpiece.

In the present work, a three dimensional transient model of the workpiece to predict the temperatures at any given location in the workpiece to predict the temperatures at any given time instance during the milling process is developed. Commercially available finite element code I-DEAS, Master Series 7 is used for simulating the cutting process and the corresponding heat transfer phenomenon. The results predicted by the FE model have been compared with the experimentally measured temperature data. Considering the predicted temperature profiles as the initial boundary conditions, the corresponding thermal distortions caused in the workpiece have been predicted. The end result of the present work would help to uncouple the dimensional error into its components, i.e., thermal elastic deflection of the workpiece and the tool.

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