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A new CAD/CAM/CAE integration approach to predicting tool deflection of end mills

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Abstract

Tool deflection of end mills caused by cutting forces has a great effect on the machining quality and efficiency. Cylindrical cantilever beam model with 80 % of tool radius is generally used to predict the tool deflection roughly. But that ignored the complex geometrical structure of end mills, which is manufactured with a set of grinding operations. In this study, the geometrical model of end mill is developed based on the CAD/CAM integration via modeling its grinding processes. Using the developed CAD model, the cutting coefficients and distributed cutting forces along the tool axis are obtained via finite element analysis of cutting simulation. Besides, the moment of inertia along the tool axis is also precisely measured based on the CAD model. Finally, with the measured inertia and distributed cutting forces, the tool defection can be predicted accurately with the unit loading algorithm for the cantilever beam. This study provides an accurate approach to predicting tool deflection of end mills based on the CAD/CAM/CAE integration.

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, Concordia University, Montreal, Quebec, Canada, H3G 1M8

    Liming Wang & Zezhong Chevy Chen

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  1. Liming Wang
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  2. Zezhong Chevy Chen
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Correspondence to Liming Wang.

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Wang, L., Chen, Z.C. A new CAD/CAM/CAE integration approach to predicting tool deflection of end mills. Int J Adv Manuf Technol 72, 1677–1686 (2014). https://doi.org/10.1007/s00170-014-5760-4

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  • DOI: https://doi.org/10.1007/s00170-014-5760-4

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