Correlating Surface Functionality with Machining Conditions in Precision Machining Processes

Abstract:

This paper attempts to correlate surface functionality generation with machining conditions by computer simulation and machining trials. The linear and nonlinear machining conditions, such as feed rate, built-up-edge, shear- localized chip formation, regenerative chatter are modelled in the light of their physical features. They are the inputs to the integrated surface topography generation model. The dynamic tool path is calculated through the dynamic cutting force model and surface response model. The surface is generated by transforming the tool profile onto the workpiece surface along the dynamic tool path. All of these models are integrated in a user-friendly Matlab Simulink environment. On the basis of the Simulink model, the dynamic simulation is performed to predict the 3D machined surface topography and its functionality. The simulation results have been validated by precision turning trials. The spectrum analysis of the machining dynamics and surface topography shows that surface generation is highly affected by the nonlinear factors in precision turning process. A case study shows the feasibility of generating some functional surface for some product/component through controlling machining variables.