Simulation virtuelle avancée pour contrôler le paramètre de coupe optimale en fraisage cinq-axes

Advanced virtual simulation for optimal cutting parameters control in five axis milling

• Auteur / Autrice : ? Hendriko
• Direction : Emmanuel Duc, Gandjar Kiswanto
• Type : Thèse de doctorat
• Discipline(s) : Génie Mécanique
• Date : Soutenance le 24/06/2014
• Etablissement(s) : Clermont-Ferrand 2
• Ecole(s) doctorale(s) : École doctorale des sciences pour l'ingénieur (Clermont-Ferrand)
• Partenaire(s) de recherche : Laboratoire : Institut Pascal (Aubière, Puy-de-Dôme) - Institut Pascal
• Jury : Président / Présidente : Henri Paris
• Jury : Examinateurs / Examinatrices : Emmanuel Duc, Gandjar Kiswanto, Hélène Chanal
• Jury : Rapporteurs / Rapporteuses : Henri Paris, Jean-Yves Hascoët

Mots clés

Mots clés contrôlés

CFAO, Systèmes de

Simulation par ordinateur

Usinage

Coupe

Fraisage (travail des métaux)

Mots clés libres

CFAO

Usinage à 5 axes

Modélisation de l’enlèvement de matière

Estimation des efforts de coupe

CAD / CAM

5 axes milling

Toroidal cutter

Material removal rate simulation

Cutting forces simulation

Résumé

La thèse concerne l’usinage à 5 axes de formes complexes. Le but est d’estimer le plus précisément possible les efforts induits par la coupe pour ajuster la vitesse d’avance et gagner en performance. Pour cela, il est nécessaire d’estimer les engagements radial et axial de la fraise à chaque instant. Ce calcul est rendu particulièrement complexe à cause de la forme de la pièce, de la forme du brut et de la complexité de la géométrie de l’outil. Les méthodes usuelles par Zbuffer sont particulièrement couteuses en temps de calcul. Dans ces travaux nous proposons une méthode de calcul rapide à partir d’une modélisation du contact dans toutes les situations envisageables. Différentes simulations et expérimentations ont permis de valider la précision expérimentalement.

This study presents a simple method to define the Cutter Workpiece Engagement (CWE) during sculptured surface machining in five-axis milling. The instantaneous CWE was defined by determining two engagement points, lowermost engagement (LE)-point and uppermost engagement (UE)-point. LE-point was calculated using a method called grazing method. Meanwhile the UE-point was calculated using a combination of discretization and analytical method. During rough milling and semi-finish milling, the workpiece surface was represented by vertical vector. The method called Toroidal–boundary was employed to obtain the UE-point when it was located on cutting tool at toroidal side. On the other hand, the method called Cylindrical-boundary was used to calculate the UE-point for flat-end cutter and cylindrical side of toroidal cutter. For a free-form workpiece surface, a hybrid method, which is a combination of analytical method and discrete method, was used. All the CWE models proposed in this study were verified and the results proved that the proposed method were accurate. The efficiency of the proposed model in generating CWE was also compared with Z-mapping method. The result confirmed that the proposed model was more efficient in term of computational time. The CWE model was also applied for supporting the method to predict cutting forces. The test results showed that the predicted cutting force has a good agreement with the cutting force generated from the experimental work.