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Journals / Erciyes Üniversitesi Fen Bilimleri Enstitüsü Fen Bilimleri Dergisi / 2022 / Cilt: 38 Sayı: 3

Correction and Compensation of Thermally-Induced Errors in CNC Milling via Integrated CAD / CAM and Finite Element Analysis for AL 7075(T6)

AL 7075 Malzemenin CNC Frezeleme İşleminde Oluşan Isıl Hataların CAD/CAM ve Sonlu Elemanlar Analizi ile Düzeltilerek İyileştirilmesi

Şaban Murat Ünlü(ERCİYES ÜNİVERSİTESİ, MÜHENDİSLİK FAKÜLTESİ, MAKİNE MÜHENDİSLİĞİ BÖLÜMÜ)0000-0001-6709-2569
Eyüp Sabri Topal(AKDENİZ ÜNİVERSİTESİ)
Ömer Faruk Ergin(ERCİYES ÜNİVERSİTESİ)
Mustafa Gül(ERCİYES ÜNİVERSİTESİ)
Pages
628–641
Publication Date
2022-12-30
DOI
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AI Summary & Key Takeaways

AI Insight
⚡ TL;DR(Too Long; Didn't Read)

In this scope, workpiece thermal expansion attitude will be analysed with finite elements method on the CAD Model, and workpiece will be revised according to the results of analysis.

📌 3 Key Takeaways

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Objective & Hypothesis:In this study, examining and correction thermal expantion induced errors on CNC milling machine is aimed.
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Key Findings & Data:The reproducibility of the performance of the correction process was investigated by processing identical samples at different manufacturing environment temperatures.
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Conclusion & Impact:In this scope, workpiece thermal expansion attitude will be analysed with finite elements method on the CAD Model, and workpiece will be revised according to the results of analysis.
🔬Design:Modeling & Simulation
📍Scope:Comprehensive Sample
⚙️Variables:Frezeleme · Isıl Hata İndirgeme · Sonlu Eleman Analizi

Abstract

In this study, examining and correction thermal expantion induced errors on CNC milling machine is aimed. In this scope, workpiece thermal expansion attitude will be analysed with finite elements method on the CAD Model, and workpiece will be revised according to the results of analysis. For revision process, an interface software is developed, making a relation between computer aided analysis modul and CAD modul. Thanks to CAM process implemented on new CAD Model, a CNC part program that will correct the error is created. The reproducibility of the performance of the correction process was investigated by processing identical samples at different manufacturing environment temperatures. As a result of studies machining errors reduced with a success rate of 84% for Al 7075(T6). By the method developed, the workpiece’s dimensional error which thermally induced can be minimized at any temperature without using climatised to ideal temperature and isolated machining shops.

Özet

Bu çalışmada CNC frezeleme işleminde ısıl değişimlerden kaynaklanan işleme hatasının incelenmesi ve düzeltilmesi hedeflenmiştir. Bu amaçla iş parçası CAD modelinin ısıl genleşme/büzülme davranışı sonlu elemanlar yöntemiyle (FEA) analiz edilmiş ve iş parçası CAD modeli bu analiz sonuçlarına göre “imalat ortamı hangi sıcaklıkta olursa olsun iş parçası tam boyutlarında işlenecek şekilde” revize edilmiştir. Revizyon işlemi için bilgisayar destekli analiz modülü ile CAD modülünü entegre eden yeni bir yazılım geliştirilmiştir. Bu yazılım ile ısıl analiz sonuçları dikkate alınarak iş parçası CAD modeli yeniden yapılandırılmıştır. Revize edilmiş yeni CAD modeli üzerinde gerçekleştirilen CAM uygulaması ile hatayı düzeltecek alternatif CNC işleme kodları elde edilmiştir. Özdeş numuneler farklı imalat ortamı sıcaklıklarında işlenerek düzeltme stratejisinin performansının tekrarlanabilirliği araştırılmıştır. Yapılan çalışma sonucunda Al7075 malzeme için %84 oranında başarı ile işleme hataları indirgenmiştir. Geliştirilen yöntemle talaşlı imalat sektöründe yüksek boyutsal kalitede parça üretebilmek için halen kullanılmakta olan, ortamın sürekli ideal sıcaklıkta (22 oC) kalması için klimatize edilmiş ve yalıtılmış atölyeler oluşturulmasına ihtiyaç kalmayacak, imalat ortamları hangi sıcaklıkta bulunursa bulunsun yüksek boyutsal tamlıkta ürünlerin üretimi ek maliyetlere katlanmaksızın mümkün olacaktır.

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Cite This Article

Ünlü, Ş. M., Topal, E. S., Ergin, Ö. F., Gül, M. (2022). Correction and Compensation of Thermally-Induced Errors in CNC Milling via Integrated CAD / CAM and Finite Element Analysis for AL 7075(T6). Erciyes Üniversitesi Fen Bilimleri Enstitüsü Fen Bilimleri Dergisi, Cilt: 38 Sayı: 3, 628–641. https://ajindex.com/articles/1266786

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