Hybrid deflection prediction for machining thin-wall titanium alloy aerospace component

Machining of aerospace structural components involves many thin-wall rib and flange sections. These thin-wall sections are dictated by design consideration to meet required strength and weight constraints. These components are either forged or cast to the approximate final shape and the end milling process is used to finish the parts. Alternatively, the component is machined from a solid block of material by end milling with roughing and finishing cuts. During machining, the cutting forces cause deflection of the thin-wall section, leading to dimensional form errors that cause the finished part to be out of specification. In this thesis, a new methodology for the prediction of wall deflection during machining of thin-wall feature is presented. The new methodology aims to increase the efficiency on modelling the deflection prediction in machining thin-wall component. The prediction methodology is based on a combination of finite element method and statistical analysis. It consists of a feature based approach of parts creation, finite element analysis of material removal and statistical regression analysis of deflection associated with cutting parameters and component attributes. The model is developed to take into account the tool-work geometries on material removal process during machining process. Mathematical models are developed for the wall deflection correlated with cutting parameters and component attributes. The prediction values have been validated by machining tests on titanium alloys parts and show good agreement between simulation model and experimental data. In addition, the cutter compensation method derived from the deflection prediction values can be used to reduce the magnitude of surface error, thus improving the component accuracy for machining thin-wall feature. By adopting the cutter compensation method, only one machining pass is required to machine the thin-wall feature. This compares favourably to the current practice in step method which requires many machining passes. All research results have been derived for four different cases of typical aerospace component, but it is shown that these results can be applicable for other component shape and materials. To assist commercial applications, a customized computer program has been developed for the hybrid model. The computer program is an integrated data exchanges between modules upon users input on the design information and machining parameter for automatically generate the solid model, material removal model and FEM analysis. The new method is able to reduce the analysis time from weeks to hours

A Methodology to Compensate for Part Compliance During Robotic Machining

Machining thin-walled, compliant parts is a cost-efficient way to manufacture lightweight and structurally sound parts as used extensively in the aerospace industry. Such parts are difficult to machine using traditional CNC machines due to part compliance, increased susceptibility to chatter, and the need for specialized tooling or fixturing devices. These challenges are heightened while machining with a robotic manipulator due to its lower stiffness and easily excited dynamics. However, due to the unique benefits of industrial robotic manipulators such as low cost and a large workspace to footprint ratio, there has been extensive research to maximize the accuracy and path compensation of robotic manipulators. This thesis introduces a methodology to compensate the path of a robotic manipulator to increase the accuracy of peripherally milled compliant parts. The research purpose is to develop an offline path compensation methodology as a solution to the part inaccuracies that occur during machining due to part compliance arising from the forces involved in machining. Two approaches to the compensation methodology are pursued in this thesis. The first approach utilizes experimentally determined dimensional errors to iteratively compensate a nominal path. In the second approach, milling force and part deflection models are used to predict the path compensation needed to compensate the part compliance induced errors. Experiments are performed on a 6-DOF industrial robotic manipulator with a laser-tracker based real-time closed-loop feedback control system. The experiments demonstrate the effectiveness of the iterative robot path compensation strategy in improving part accuracy. The benefits and implications of the compensation strategy are discussed and future improvements to the methodology are recommended.M.S

Analysis, optimization, FE simulation of micro-cutting processes and integration between Machining and Additive Manufacturing.

La seguente Tesi di Dottorato riguarda i processi di Micro-Machining (MM) applicati su materiali ottenuti per fabbricazione additiva. I processi MM sono un insieme di tecnologie di produzione utilizzate per fabbricare componenti o realizzare features di piccole dimensioni. In generale, i processi di taglio sono caratterizzati da un'interazione meccanica tra un pezzo e un utensile che avviene lungo una determinata traiettoria. Il contatto determina una rottura del materiale lungo un percorso definito, ottenendo diverse forme del pezzo. Più precisamente, la denominazione di microlavorazione indica solo le lavorazioni di taglio eseguite utilizzando un utensile di diametro inferiore a 1 mm. La riduzione della scala dimensionale del processo introduce alcune criticità non presenti negli analoghi processi su scala convenzionale, come l'effetto dimensionale, la formazione di bave, la rapida usura dell'utensile, le forze di taglio superiori alle attese e l'eccentricità del moto dell'utensile. Negli ultimi decenni, diversi ricercatori hanno affrontato problemi relativi alla microlavorazione, ma pochi di loro si sono concentrati sulla lavorabilità dei materiali prodotti per Additive Manufacturing (AM). L’AM è un insieme di processi di fabbricazione strato per strato che possono essere impiegati con successo utilizzando polimeri, ceramica e metalli. L'AM dei metalli si sta rapidamente diffondendo nella produzione industriale trovando applicazioni in diversi rami, come l'industria aerospaziale e biomedica. D’altro canto, la qualità del prodotto finale non è comparabile con gli standard ottenibili mediante i metodi convenzionali di rimozione del materiale. Lo svantaggio principale dei componenti realizzati mediante AM è la bassa qualità della finitura superficiale e l'elevata rugosità; pertanto, sono solitamente necessari ulteriori trattamenti superficiali post-processo per adeguare le superfici del prodotto ai requisiti di integrità superficiale. L'integrazione tra le due tecnologie manifatturiere offre opportunità rilevanti, ma la necessità di ulteriori studi e indagini è evidenziata dalla mancanza di pubblicazioni su questo argomento. Questa ricerca mira ad esplorare diversi problemi connessi alla microlavorazione di leghe metalliche prodotte mediante AM. Le prove sperimentali sono state eseguite utilizzando il centro di lavoro ultrapreciso a 5 assi “KERN Pyramid Nano”, mentre i campioni AM sono stati forniti da aziende e gruppi di ricerca. L'attrezzatura sperimentale è stata predisposta per eseguire la micro-fresatura e per monitorare il processo in linea misurando la forza di taglio. Il comportamento di rimozione del materiale è stato studiato e descritto per mezzo di modelli analitici e simulazioni FEM. I metodi FE sono stati utilizzati anche per eseguire un confronto tra le forze di taglio previste e i carichi sperimentali, con lo scopo finale di affinare la legge di flusso dei materiali lavorati. La ricerca futura sarà focalizzata sulla simulazione FE dell'usura dell'utensile e dell'integrità della superficie del pezzo.This thesis is focused on Micro-Machining (MM) processes applied on Additively Manufactured parts. MM processes are a class of manufacturing technology designed to produce small size components. In general, cutting processes are characterized by a mechanical interaction between a workpiece and a tool. The contact determines a material breakage along a defined path, obtaining different workpiece shapes. More specifically, the micro-machining designation indicates only the cutting processes performed by using a tool with a diameter lower than 1 mm. The reduction of the process scale introduces some critical issues, such as size effect, burr formation, rapid tool wear, higher than expected cutting forces and tool run-out. In the last decades, several researchers have tackled micro-machining related issues, but few of them focused on workability of Additive Manufactured materials. Additive Manufacturing (AM) is a collection of layer-by-layer building processes which can be successfully employed using polymers, ceramics and metals. AM of metals is rapidly spreading throughout the industrial manufacturing finding applications in several branches, such as aerospace and biomedical industries. Moreover, the final product quality is not comparable with the standards achievable through the conventional subtractive material removal methods. The main drawback of additively manufactured components in metals is the low quality of the surface finish and the high surface roughness, therefore further post-process surface treatments are usually required to finish and to refine the surfaces of the build product. The embedding between the two technologies offers relevant opportunities, but the necessity of further studies and investigation is highlighted by the lack of publication about this topic. This research aimed to explore several micro-machining issues with regards to Additive Manufactured metals. Experimental tests were performed by using the ultraprecision 5-axes machining center “KERN Pyramid Nano”, while the AM samples were provided by companies and research groups. The experimental equipment was set-up to perform micro-milling and to monitor the process online by measuring the cutting force. The material removal behavior was investigated and described by means of analytical models and FEM simulations. FE methods were employed also to perform a comparison between the predicted cutting forces and the experimental loads, with the final purpose of refining the flow stress law of the machined materials. The future research will be focused on the FE simulation of the tool wear and the workpiece surface integrity by means of specific subroutines

Numerical simulation for milling processes of thin wall structures

Ph

Prediction and compensation of geometrical errors in milling process of thin components using a flexible configuration setup

In this study, a prediction model based on finite element analysis is developed to predict cutting errors during the machining process of thin plates using a flexible setup configuration. The model is based on analysis of the material deformation of thin plates under the action of axial cutting forces using a specifically designed test bed to reproduce commonly used flexible setup in industry. The cutting process is simplified as a static analysis of the material deformation under the effect of the applied cutting forces. In the analysis, different positions of the cutting tool during the machining process are studied to determine the workpiece’s geometrical profiles during milling. Several analyses are carried out for different positions of the cutting tool. The cutting force is also modeled to predict the cutting force for specific cutting conditions. This cutting force model is utilized as input to the finite element analysis of the material deformation of the workpiece during the machining process. The experimental system is also designed to conduct tests with different cutting conditions on the three-axis Huron K2X10 CNC milling machine to verify the predicted results obtained from the analysis model. The geometrical errors of the machined plates after machining are determined by using the Mitutoyo Bright Strato Coordinate Measurement Machine (CMM) to measure their geometrical profiles before and after machining processes. Finally, the mirror technique is utilized to compensate cutting deviations based on the predicted results of the workpiece’s displacements. Adding the value from the prediction model to the designed cutting depth creates the updated tool path. The results show good agreement in the prediction of the thin plate deformation during the machining as compared to the experimental tests

The comprehensive analysis of milling stability and surface location error with considering the dynamics of workpiece

Cutting movement is still one of the main means to obtain the desired machined surface. As the most representative cutting method in subtractive manufacturing, milling is widely used in industrial production. However, the chatter induced by the dynamic interaction between machine tool and process not only reduces the accuracy of the machined workpiece, but also increases the tool wear and affects the rotary accuracy of the spindle. The stability lobe diagram can provide stable machining parameters for the technicians, and it is currently an effective way to avoid chatter. In fact, the dynamic interaction between the machine tool and process is very complicated, which involves the machine tool, milling tool, workpiece and fixture. The induced mechanism of chatter depends on different machining scenarios and is not entirely dependent on the vibration modes of milling tool. Therefore, it is important to obtain stable machining parameters and to know the dynamic surface location error distribution, which can ensure machining quality and improve machining efficiency. In this dissertation, two methods for constructing stability lobe diagram are first introduced, and then two machining scales, macro milling and micro milling, are studied. For the macro-milling scale, the dynamic response of the in-process workpiece with time-varying modal parameters during the material removal process is analyzed. The stability lobe diagrams for thin-walled workpiece and general workpiece with continuous radial immersion milling are established respectively. Besides, the cumulative surface location error distribution is also studied and verified for the general workpiece. For the micro-milling scale, the dynamics at the micro-milling tool point is obtained by means of the receptance coupling substructure analysis method. The stability lobe diagram and surface location error distribution are analyzed under different restricted/free tool overhang lengths. The relationship between measurement results and burrs is further explained by cutting experiments, and the difference between the two milling scales is compared in the end

Optimization of Cutting Parameters for Pocket Milling on the Skin Plate in Al and Al-Li Materials

RÉSUMÉ L'objectif de cette étude est d'optimiser des paramètres de coupes pour l’usinage de poche sur une plaque mince en alliage d’aluminium et en alliage d’aluminium-lithium. Ces plaques minces sont utilisées dans l’industrie aéronautique pour fabriquer le fuselage d’un avion. Présentement, ces poches sur les plaques minces sont fabriquées par usinage chimique. Cette méthode chimique est dite nocive pour l’environnement. La méthode chimique pourrait être remplacée par une méthode mécanique comme l’usinage. En plus, les paramètres de coupes seront optimisés pour l’alliage d’aluminium-lithium. L’effet des paramètres de coupes a été étudié par des expériences utilisant la méthode de Taguchi. L’analyse de rapport signal sur bruit (Signal to Noise ratio) a été menée sur les données recueillies pour illustrer la significativité des facteurs des plans d’expériences et de leur contribution. La rugosité de la surface sur les pièces a été aussi étudiée et des paramètres optimaux ont été définis. Des vérifications ont été accomplies et la poche sur la plaque a été usinée à la satisfaction des exigences de l'ingénierie de l'industrie.----------ABSTRACT In the present work the pocket machining (milling) of the thin skin components made of aluminium and aluminium-lithium (Al-Li) alloys is studied. These milled components are known as principle parts of commercial airplanes. They have significant impacts on the airplane body weight and fuel consumption. Chemical milling is the main method used for pockets machining on these components. However, this method is not considered as an environmentally friendly operation due to severe contamination problems. To remedy these difficulties, this study intends to replace the chemical milling by an alternative machining method capable to do pocket machining. To that end, pocket milling was selected as machining method. Furthermore, in order to reduce the weight of airplane, an alternative material such as Al-Li alloys is proposed to replace the aluminum alloys. In the first phase of this study, a comprehensive literature review was conducted on milling and pocket milling of aluminum and aluminum-lithium alloys. The sample parts required for cutting operations were prepared in accordance with in specified dimensional geometries of the real parts used in industry. A milling fixture was then designed and manufactured in order to perform machining operations on the sample parts. The experimental tests were planned according to the Taguchi method design of experiment. The cutting parameters studied included: RPM, chip thickness (feed rate), depth of cut and lubricant. The one way and profile contouring milling operations were selected as machining strategies. A process failure mode and effect analysis (FMEA) was executed to determine the main failure modes during pocket milling operations and the surface roughness was used as performance criteria. The experimental results were analyzed using Signal to Noise ratio (S/N) strategy though Taguchi method. According to the experimental results, the optimal setting levels of cutting parameters are RPM (10000 rev/min), chip thickness (0.0508 mm), depth of cut (0.45 mm) and lubricant (MQL, 40 ml/min). Finally, the experimental verification tests were performed. According to the literature, a similar machining specification can be applied for conventional aluminium alloys and the Al-Li alloys. Consequently, in order to reduce the experimental cost and time, the optimum setting levels of process parameters proposed in this work could be applied in the machining of Al-Li work pieces

Alternative experimental methods for machine tool dynamics identification: A review

An accurate machine dynamic characterization is essential to properly describe the dynamic response of the machine or predict its cutting stability. However, it has been demonstrated that current conventional dynamic characterization methods are often not reliable enough to be used as valuable input data. For this reason, alternative experimental methods to conventional dynamic characterization methods have been developed to increase the quality of the obtained data. These methods consider additional effects which influence the dynamic behavior of the machine and cannot be captured by standard methods. In this work, a review of the different machine tool dynamic identification methods is done, remarking the advantages and drawbacks of each method.The present work has been partially supported by the EU Horizon 2020 InterQ project (958357/H2020-EU.2.1.5.1.) and the CDTI CERVERA programme MIRAGED project (EXP-00,137,312/CER-20191001)