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用于数控铣削和车削的虚拟加工系统.pdf
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HAL Id: hal-03024769
https://hal.science/hal-03024769
Submitted on 11 Dec 2020
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Virtual Machining Systems for CNC Milling and
Turning Machine Tools: A Review
Mohsen Soori, Behrooz Arezoo
To cite this version:
Mohsen Soori, Behrooz Arezoo. Virtual Machining Systems for CNC Milling and Turning Machine
Tools: A Review. International Journal of Engineering and Future Technology, In press, 18 (1),
pp.56-104. �hal-03024769�
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Virtual manufacturing systems are developed by simulating real manufacturing processes in digital
environments in order to increase accuracy as well as efficiency of part production. Accuracy of the
produced parts can be increased by errors can also be analyzed and decreased by using virtual
machining systems. Moreover, optimization methods can be applied to the simulated
manufacturing processes in the virtual environments to improve efficiency of part production by
using optimized cutting conditions. Elements of machine tools can be simulated, analyzed and
modified by using virtual machining system. The simulated machining processes in virtual
environments can be used in training monitoring and analyzing errors of simulated manufacturing
processes in virtual environments. In order to boost accuracy of produced parts, effects of
machining operation errors such as dimensional, geometrical, thermal and tool deflection programs
without the need of shop floor testing. The most suitable methods of part production can be
selected by applying process planning methodologies to the simulated manufacturing processes in
the virtual environments. Furthermore, the parts can be analyzed in virtual environments using the
Finite Element Method (FEM) to provide the error effects analysis. In this paper, a review of virtual
machining systems for CNC milling as well as turning machine tools is presented and future
research works are also suggested. As a result, it is hoped that the research filed can be moved
forward by reviewing and analyzing recent achievements in the published papers.
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International Journal of Engineering and Future Technology,
Year 2021; Volume 18; Issue No. 1;
ISSN 2455-6432
Copyright © 2021, International Journal of Engineering and Future Technology
ISSN 2455-6432
www.ceser.in/ceserp
www.ceserp.com/cp-jou
r
detection by using virtual machining system. The operators of machine tools can initially be trained by
virtual machining environments. Process planning methodologies can be applied in virtual
environments in order to select the most suitable methods of part production. To provide ability of
error effect analysis, machined parts can be simulated and analyzed in virtual environments using the
Finite Element Methods (FEM). Therefore, stress and strain of produced parts can be measured and
analyzed in order to increase accuracy as well as reliability of part manufacturing.
Based on the authors’ findings to date, it was determined that the review paper in the virtual
machining systems for CNC milling and turning machine tools is insufficiently explored. Web-based
virtual machine tool systems are considered by Kadir et al. (Kadir, Xu, and Hämmerle 2011) in order
to present a review paper. In this paper, developed version of review article in virtual machining
systems is presented by considering the all published papers in all research fields used by virtual
technology including design, simulation, optimization, scheduling, process planning, monitoring
systems, configuration for CNC milling and turning machine tools. In the research work, a review of
virtual machining systems from the 173 published papers dated from 1995 to 2018 for CNC milling
and turning machine tools is presented. Virtual machining systems and applications for CNC milling
and turning machine tools are presented in the study by reviewing and analyzing recent achievements
from published papers. As a result, new ideas in virtual machining systems are introduced to the
researchers in order to push forward this interesting research field.
Section 2 presents a review from research works related to applications of virtual machining systems
in simulation of cutting forces, dimensional, geometrical and tool deflection errors. Review of research
works related to virtual machining systems for CNC milling machine tools is presented in section 3. A
review of research works related to virtual machining systems for CNC turning machine tools is
presented in section 4. Section 5 presents review of research works related to virtual machining
systems for CNC turn-mill machine tools. Finally, conclusion of the research work as well as future
studies in virtual machining systems are presented in the section 6 and 7 respectively.
2. REVIEW OF VIRTUAL MACHINING SYSTEMS IN SIMULATION OF CUTTING FORCES,
DIMENSIONAL, GEOMETRICAL AND TOOL DEFLECTION ERRORS
This section covers research articles dated from 1995 to 2017 focusing on the methods used in the
modeling of milling operations in virtual environments. The methodologies applied in modeling of
cutting forces, dimensional and geometrical errors tool deflection error for CNC milling machine tools.
Modeling methodologies of cutting forces, dimensional, geometrical and tool deflection errors are
described in the section 2 which are used by the presented virtual machining systems in the sections
3 and 5.
2.1. Cutting force models
A virtual machining system is developed by Maekawa et al. (Maekawa, Shirakashi, and Obikawa 1995)
to simulate and analyze chip flow, cutting forces, cutting temperature, fracture probability of cutting
tool and tool wear of milling machines tools in virtual environments. The outlines of finite-element
simulation theory and modeling and typical simulation results are presented in the study to develop
machining simulation systems. In order to estimate tool wear as well as cutting forces in turning
operations, a virtual cutting system using artificial neural networks is presented by Wang et al. (Wang
et al. 2005). In this paper, a virtual cutting system is presented which can simulate turning process,
estimate tool wear and cutting force using artificial neural network. This approach enables designers
International Journal of Engineering and Future Technology
57
to evaluate and modify effective parameters of machining processes in order to increase accuracy
and efficiency of part production.
Virtual simulation of three and five-axis milling operations is presented by Boz et al. (Boz, Erdim, and
Lazoglu 2015) to develop prediction of cutting forces by different methods of cutter-workpiece
engagement. In order to obtain desired surface quality and productivity, process parameters such as
feed rate, spindle speed, and axial and radial depths of cut are appropriately selected by using the
developed virtual milling system in the study. Tunç et al. (Tunç, Ozkirimli, and Budak 2016) presented
a virtual machining system in order to develop machining strategy, based on process simulations in 5-
axis milling machine tools. To obtain cutting parameters in machining operations, cutting forces are
simulated through extended Z-mapping approach. To calculate the chatter stability in milling
operations, stability diagrams are generated in frequency domain. Cutting torque, spindle power, tool
deflection and surface roughness are considered to present dynamic programming for machining
strategy.
Prediction of cutting forces in three and five-axis ball-end milling is presented by Tuysuz et al. (Tuysuz,
Altintas, and Feng 2013). A methodology is presented by Lai (Lai 2000) in order to calculate cutting
forces of milling operations in virtual environments. Effective parameters of cutting forces such as
radial and axial depths of cut, cutting feed rate are considered in a study to present a modeling
methodology for cutting forces. Simulation of cutting forces based on numerical methods in ball-end
milling operations is presented by Milfelner and Cus (Milfelner and Cus 2003).
The cutting forces in ball-end milling operations of sculptured surfaces are calculated by Kim et al.
(Kim, Cho, and Chu 2000) To determine engagement of cutting edge elements to the workpice in
machining operations, the cutting edge elements are projected onto the cutter plane normal to the Z-
axis. Then, cutting forces acting on the engaged elements of cutting edges are calculated by using
empirical methods. As a result, the cutting forces are described in the study by mathematical concepts
in order to be used in virtual simulation. Ferry et al. (Ferry and Altintas 2008a) developed a virtual
machining system to predict cutting forces in five-axis machining operations.
A virtual machining system is developed by Yun et al. (Yun, Ko, Lee, et al. 2002) to simulate cutting
processes in transient cuts in flat end-milling process. To simulate cutting processes, the cutting
forces as well as surface errors are predicted in the study. Z-map calculation errors are developed in
the study to calculate the cutting configuration for a given NC codes. The model can use edge nodes
methodology in order to accurately describe each position of contact point between cutting tool as well
as workpiece along machining paths. Thus, a virtual machining system is presented in the study to
simulate cutting processes of multiple two-dimensional cutter paths which is a useful tool for process
planners. Web-based virtual machining and measuring cell is developed by Yao et al. (Yao, Liu, and
Li 2005) to predict cutting forces along machining paths in virtual environments. Predicted cutting
forces, applied forces to cutting tool and calculated shape error due to tool deflection are considered
by Dow et al. (Dow, Miller, and Garrard 2004) in order to present a technique in virtual environments
to compensate deflection error of small milling tools.
A Virtual machining is presented by Uhlmann et al. (Uhlmann et al. 2017) in order to predict cutting
forces as well as surface quality in micro-milling operations. Therefore, accuracy of produced parts in
micro-milling operations can be analyzed and increased by using the developed system in the study.
To calculate the cutting forces in milling operations, a method is presented by Engin and Altintas .
(Engin and Altintas 2001) Fig. 1 shows a typical milling operation with a general end mill (Engin and
Altintas 2001).
International Journal of Engineering and Future Technology
58
Fig. 1 Mechanics and kinematics of three-axis milling (Engin and Altintas 2001).
Where
pj
I
is pitch angle of flute j,
()
j
z
I
is total angular rotation of flute j at level z on the XY plane,
()z
\
is radial lag angle and
()z
N
is axial immersion angle. In the differential chip,
dz
is differential
height of the chip segment,
ds
is the length of cutting edge and
j
h
is height of valid cutting edge from
tool tip.
The differential tangential
()
t
dF
, radial
()
r
dF
and axial
()
a
dF
cutting forces acting on an
infinitesimal cutting edge segment are given in Eq. (1) (Engin and Altintas 2001).
°
¯
°
®
dbkhKdsKdF
dbkhKdsKdF
dbkhKdsKdF
jacaea
jrcrer
jtctet
),(
),(
),(
M
M
M
(1)
Where
(,)
j
hk
I
is the uncut chip thickness normal to the cutting edge and varies with the position of
the cutting point and cutter rotation.
In flat end milling operation, the uncut chip thickness is presented by Erdim et al. (Erdim, Lazoglu, and
Ozturk 2006) as is shown in Eq. (2).
)(),(
jtjj
SinSkh
MM
(2)
Where
tj
S
and
j
I
are feed per tooth and radial lag angle of tooth j respectively.
db
is the projected length of an infinitesimal cutting flute in the direction along the cutting velocity
which can be shown as Eq. (3) (Engin and Altintas 2001).
SinK
dz
db
(3)
Once the chip load is identified and cutting coefficients are evaluated for the local edge geometry, the
cutting forces in cartesian coordinate system can be evaluated as Eq. (4) (Engin and Altintas 2001).
»
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»
¼
º
«
«
«
¬
ª
a
t
r
jjj
jjj
Z
y
x
dF
dF
dF
dF
dF
dF
NN
NMMNM
NMMNM
sin0cos
coscossinsincos
cossincossinsin
(4)
International Journal of Engineering and Future Technology
59
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