Modelling and simulation environment for machining of low-rigidity components

Machining of low-rigidity components is a key process in industries such as aerospace, marine engineering and power engineering. The part deflection caused by the cutting force due to the flexible part structure reduces the validity of the CAM output and leads to additional machining errors that are difficult to predict and control. The paper reports a modelling methodology and integration architecture for multi-step simulation of cutting processes of low-rigidity components incorporating a finite element analysis (FEA)-based component model, FE analysis tool, force model and material removal algorithm. The FEA-based data model of low-rigidity component is proposed based on describing key object-oriented classes such as component, element, node and force to create a common integrated decision making environment. Each object has unique decision making methods associated with it that allow seamless integration in simulating the part behaviour during machining. Two iterative algorithms are proposed within the simulation environment for cutting force prediction and material removal simulation. A prototype version of the simulation environment has been developed using C++, and the feasibility of the proposed approach has been illustrated using practical examples backed up by experimental data.