Numerical and Experimental Studies on Fixture-Workpiece Contact and Structural Deformations in Pocket Milling

DOI

10.2991/iccasp-16.2017.35How to use a DOI?

Keywords

Hertzian contact, workpiece compliance, fixture-workpiece, adaptive clamping, metal removal effect

Abstract

Geometrical inaccuracies, in a statically clamped workpiece subjected to cutting forces, are mainly caused by the contact deformations at the locators and the structural deformations in the body of the workpiece. In addition, during machining the structural deformations continuously increase as the workpiece keeps losing its stiffness on account of metal removal. This condition is also encountered while machining thin walled workpieces. To investigate the relative significance of the structural and the contact deformations, fixture elements workpiece and the contact at their interface is modelled numerically in ANSYS 17.2.A milling fixture with 3-2-1 location principle and two hydraulically operated clamps is developed for pocket milling operation on Al-6061-T6 and a number of experiments are conducted to obtain structural deformation of workpiece. The numerical simulations and experiments were performed for different percentages of metal removal (0%, 20% and 50%) under various clamping pressures varying from 15-25 bar (kg/cm2).The numerically predicted deformations show a good agreement with experimental results. The studies would help in developing an adaptive clamping mechanism to compensate for the changing structural stiffness of the workpiece and thereby keeping a check on the deformations, and hence the machining accuracies.

Copyright

© 2017, the Authors. Published by Atlantis Press.

Open Access

This is an open access article distributed under the CC BY-NC license (http://creativecommons.org/licenses/by-nc/4.0/).

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TY  - CONF
AU  - M. Yadav
AU  - S. Mohite
PY  - 2016/12
DA  - 2016/12
TI  - Numerical and Experimental Studies on Fixture-Workpiece Contact and Structural Deformations in Pocket Milling
BT  - Proceedings of the International Conference on Communication and Signal Processing 2016 (ICCASP 2016)
PB  - Atlantis Press
SP  - 212
EP  - 219
SN  - 1951-6851
UR  - https://doi.org/10.2991/iccasp-16.2017.35
DO  - 10.2991/iccasp-16.2017.35
ID  - Yadav2016/12
ER  -