Three-Dimensional Finite Element Based Numerical Simulation of Machining of Thin-Wall Components with Varying Wall Constraints

Control of part deflection and deformation during machining of low rigidity thin-wall components is an important aspect in the manufacture of desired quality products. This paper presents a comparative study on the effect of geometry constraints on the product quality during machining of thin-wall components made of an aerospace alloy aluminum 2024-T351. Three-dimensional nonlinear finite element (FE) based simulations of machining of thin-wall parts were carried out by considering three variations in the wall constraint viz. free wall, wall constrained at one end, and wall with constraints at both the ends. Lagrangian formulation based transient FE model has been developed to simulate the interaction between the workpiece and helical milling cutter. Johnson–Cook material and damage model were adopted to account for material behavior during machining process; damage initiation and chip separation. A modified Coulomb friction model was employed to define the contact between the cutting tool and the workpiece. The numerical model was validated with experimental results and found to be in good agreement. Based on the simulation results it was noted that deflection and deformation were maximum in the thin-wall constrained at one end in comparison with those obtained in other cases. It was noted that three dimensional finite element simulations help in a better way to predict the product quality during precision manufacturing of thin-wall components. © 2016, The Institution of Engineers (India).