Modelling of dimensional and geometric error prediction in turning of thin-walled components

In die-mold manufacturing and aircraft industry, many components that have thin-walled features are produced by turning operation. The major problem encountered during internal or external turning is cutting force induced deflection of workpiece along the periphery as well as axial length of a component. The present research work aims to develop a mathematical model for estimating dimensional and geometric errors during turning of thin-walled hollow cylinder qualitatively and quantitatively. In the proposed model, a mechanistic approach which is semi-analytical in nature is followed to achieve accuracy of the predicting results. First of all, process geometry model for thin-wall turning is developed based on process geometry variables such as uncut chip thickness, actual feed per revolution, actual depth of cut, peripheral cutting speed, effective cutting area etc. Using these process geometry variables and mechanistic cutting constants, a force model of turning is developed to estimate the tangential and radial force components. Later on, based on the predicted forces, tool-workpiece combined deflection model is developed to estimate radial, diametric and various geometric errors of the turned surface. The developed models are able to predict radial, diametric and various geometric errors such as straightness, circularly and cylindricity errors without conducting expensive actual machining operation. Hence, the present study will be helpful to take care of precautionary measures for controlling of dimensional and geometric errors more efficiently and reliably. Therefore, an attempt has been made to provide a basic platform to machining practitioners and process planners for in-depth comprehension and characterization of dimensional and geometric errors of the entire turned surface for varying machining conditions.