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Face Milling Simulation to Correlate and Predict The Effects of Machine Tool Geometric Errors on Part Flatness Tolerance

Iyer, Vipin V
http://rave.ohiolink.edu/etdc/view?acc_num=ucin1406881376

Abstract Details

2014, MS, University of Cincinnati, Engineering and Applied Science: Mechanical Engineering.
Face milling using a three or five axis machining center is one of the most common forms of metal manufacturing processes in the world. The simplicity of the process and the accuracy of the part it produces makes it the default machining process to use for a roughing cut and finishing a surface. This research focuses on theoretically simulating a surface cut by the intermittent cutting action of a multi-point face mill cutting tool by partitioning the surface into grids. The points on the surface of each grid that have the lowest depth of cut value represent the imprint of the cutting tool on the finished surface. Machine tool geometric errors are typically present in any milling machine in a cold start condition and tend to progressively get worse over time. This finished surface is virtually generated while taking into account machine tool geometric errors from each of the machining center’s slides as well as the spindle errors by virtual modeling of the machining process. The finished surface is then virtually inspected to determine flatness error, a form tolerance, which is one of the metrics for part accuracy. A statistical treatment of error combinations is used to determine which machine tool geometric error components of a particular slide have a significant and practical impact on part accuracy defined by the flatness error. This could help improve accuracy during machining since the operator can avoid setting the slides of the machining center to locations that have higher calculated error values for these significant error terms. The study of the effect of these machine tool geometric errors of each machine slide on flatness error can be used to determine parameters of error compensation to help improve part accuracy at end of machine life. Selective error compensation might be cheaper at the end of machine life than complete machine overhaul.
Sundararaman Anand, Ph.D. (Committee Chair)
Sundaram Murali Meenakshi, Ph.D. (Committee Member)
David Thompson, Ph.D. (Committee Member)
65 p.
Mechanics
face milling; simulation; design of experiments

Recommended Citations

Citations

  • Iyer, V. V. (2014). Face Milling Simulation to Correlate and Predict The Effects of Machine Tool Geometric Errors on Part Flatness Tolerance [Master's thesis, University of Cincinnati]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1406881376

    APA Style (7th edition)

  • Iyer, Vipin. Face Milling Simulation to Correlate and Predict The Effects of Machine Tool Geometric Errors on Part Flatness Tolerance. 2014. University of Cincinnati, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ucin1406881376.

    MLA Style (8th edition)

  • Iyer, Vipin. "Face Milling Simulation to Correlate and Predict The Effects of Machine Tool Geometric Errors on Part Flatness Tolerance." Master's thesis, University of Cincinnati, 2014. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1406881376

    Chicago Manual of Style (17th edition)

ucin1406881376
1,221
© 2014, all rights reserved.
This open access ETD is published by University of Cincinnati and OhioLINK.