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Abstract
During the micromachining of hardened materials, the low stiffness of the milling tool results in an increased tool deflection which
has a great influence on the shape and dimensional accuracy of the machined components. In order to compensate these deflections,
an optimization method is presented in this paper. Based on measured form errors of the machined workpieces, the NC programs
are optimized iteratively to reduce the shape deviations. To verify this method, experimental investigations were carried out by
milling pockets in hardened steel. The results show a significant reduction of the tool deflection after the optimization.
2012
2012 The Authors.
Published byPublished by Elsevier
Elsevier BV. B.V.and/or
Selection Selection and/or peer-review
peer-review under responsibility
under responsibility of Professor
of Prof. Dr. Konrad Wegener
Konrad Wegener
2212-8271 2012 The Authors. Published by Elsevier B.V. Selection and/or peer-review under responsibility of Professor Konrad Wegener
http://dx.doi.org/10.1016/j.procir.2012.04.022
D. Biermann et al. / Procedia CIRP 1 (2012) 132 137 133
forming tools in sheet metal forming have been modified in order to compensate the form errors caused by tool
in order to compensate the shape deviations caused by deflection, the tool positions can be directly displaced by
springback. This procedure can be applied for the the function F with respect to a set of deformation
compensation of form errors in micromilling caused by vectors. Using this approach, the NC programs with
tool deflections in the same manner. several thousands of points can be optimized in a few
A great challenge of this approach is to find a smooth minutes.
deformation function, which approximates the discrete
deformation field and can be used for adjusting the tool 3. Experimental setup
positions. Due to the noise in the measured data, it is
important to define a deformation function including In order to verify the presented approach, small
smoothing properties. A well-known technique, which pockets of dimensions 5 mm x 5 mm with a corner
can be used for this purpose, is a B-spline based free- radius of 1.5 mm were machined. In order to analyze the
form deformation [9, 15]. It pointwisely deforms the effect on the resulting shape deviation, the width of cut
space and all the 3D objects inside the space by applying ae was varied as follows. Experiment A is conducted
a continuous function F: 3 to all points of the using a width of cut ae = 200 m, experiment B
objects. The new position of an arbitrary point p is ae = 400 m, and experiment C ae = 600 m. Each
defined as a trivariate weighted sum of control points experiment was performed for three times. The
Pi,j,k: remaining cutting parameters are set according to
fundamental investigations of Biermann et al. [3]. Fig 3
l ,m,n gives an overview of the parameters.
p ' = F (u , v, w) = B (u) B (v) B (w) P
i , j , k =1
i j k i , j ,k (1)
5. Conclusion Acknowledgements
In micromachining, deviations from the ideal This work was supported by the German Research
geometry cannot be avoided completely. An enormous Foundation (DFG) within the scope of the Transregional
tool deflection of about 100 microns was measured, Collaborative Research Centre on sheet-bulk metal
particularly, when using tools with a cantilever length to forming (SFB/TR73) in the subproject B2 and the
machine deep cavities in hardened steel. SFB708 in the subproject C4.
In order to compensate deflections of the milling tool
and to achieve a high shape accuracy, a new method was
presented in this paper. Based on measured data, the References
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