Authors: S.V. Gaist, A.M. Markov, S.L. Leonov, V.N. Nekrasov

Title of the article: Prediction of deformation of a fiberglass body part with non-rigid walls during milling

Year: 2025, Issue: 3, Pages: 42-50

Branch of knowledge: 2.5.6. Engineering technology

Index UDK: 621.914

DOI: 10.26730/1999-4125-2025-3-42-50

Abstract: The paper presents a method for predicting the elastic deformation of a body part with non-rigid fiberglass walls during milling using dimensionless dependencies. With the widespread introduction of composite materials into machine-building production, a significant number of products require mechanical processing, including body parts. One of the important problems that arise when cutting fiberglass is its significant elastic deformation from the action of cutting forces. The problem is compounded in the case of processing parts with non-rigid elements, in particular with non-rigid walls. The solution can be found in the assignment of rational cutting modes, characterized by a change in the processing process to control the cutting force, thus ensuring equality of the cut allowance and sufficient processing accuracy. For hard sections, the modes can be tightened, thereby increasing productivity. A reasonable approach for choosing cutting modes is to simulate the elastic deformation of a part during machining. One of the modeling methods showing reliable results is the finite element method (FEM). But its application involves the use of expensive software, significant computing power and a lot of time. As an alternative, the paper suggests using a model based on dimensionless dependencies, which can be built on the basis of experimental data or FEM modeling results. The obtained model makes it possible to predict the elastic deformation of the non-rigid wall of the body part at specified parameters of the part and cutting modes. The assessment of the adequacy of the model showed that the error of the simulation results compared to the FEM does not exceed 10%, which can be considered a good indicator for practical use.

Key words: modeling dimensionless dependencies fiberglass milling non-rigid walls deformation precision machining

Receiving date: 25.05.2025

Approval date: 10.06.2025

Publication date: 26.06.2025

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