Numerical modelling of diameter errors in slender bar turning with movable support

摘要

Prediction of machining accuracy is an essential prerequisite for optimization of machining processes. In this study, a numerical model is developed to predict diameter errors in slender bar turning operations. Special attention is paid to the effect of the movable support on diameter error during machining process. The proposed model uses a geometric analysis in the machine frame, in which the elastic deflections of the machine-tool-part system due to cutting force are studied by finite element method. Further, for the coupling between cutting force and actual depth of cut, iterative calculation is carried out to obtain the coupling value of the cutting depth which provides further accuracy to the prediction. Finally, numerical examples are provided to investigate the effects of mounting method and movable support stiffness on diameter errors. Experimental results show that the developed model has the ability to predict efficiently the diameter errors for slender bar turning operations.