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Machining error model for full machining process of thread milling

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Abstract

Thread milling is increasingly used in engineering manufacturing because of its advantages, but there must be some error in the thread due to the machining principle. In response to this problem, this paper discussed the causes of thread milling error and established the machining error model for the full machining process of thread milling. Firstly, the geometric model of thread milling is developed based on the parametric definitions of the cutter tooth surface, thread surface, and tool-path. Then, based on the cutter motion characteristics of the thread milling penetration and retraction segments and machining segment, the machining error model is established. The calculation of machining error is transformed into solving for the relationship between the position of the intersection of the cutter profile line and the thread profile line generated in the cross-section, which means that the three-dimensional problem is transformed into the two-dimensional problem. Finally, the proposed model is proven via thread milling experiments. The simulation results of machining error agree well with the experimental results, which prove the correctness and validity of the model. The model provides theoretical support for further research into thread milling machining error.

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Availability of data and material

All data and materials used or analyses during the current study are included in this manuscript. The data and results are true and clear.

Code availability

The calculation was performed based on the MATLAB software.

Abbreviations

TP:

Thread profile

CP:

Cutter tooth profile

TS:

Standard thread surface

CS:

Cutter tooth surface

PTS:

Produced thread surface

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Funding

This work is supported by the National Science and Technology Major Project (Grant No. J2019-VII-0001–0141).

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Authors and Affiliations

  1. Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, People’s Republic of China

    Yuanhao Fan & Junxue Ren

  2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, People’s Republic of China

    Yuanhao Fan & Junxue Ren

  3. School of Mechanical Engineering and Mechanics, Xiangtan University, Xiangtan, 411100, People’s Republic of China

    Zihua Hu

  4. Key Lab of Manufacturing Equipment of Shanxi Province, School of Mechanical and Precision Instrument Engineering, Xi’an University of Technology, Xi’an, 710048, People’s Republic of China

    Yiran Tang

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  1. Yuanhao Fan
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Contributions

Yuanhao Fan, methodology, investigation, formal analysis, and writing draft. Yiran Tang, editing and review. Junxue Ren, project administration, supervision, and review. Zihua Hu, review.

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Correspondence to Junxue Ren.

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Fan, Y., Ren, J., Hu, Z. et al. Machining error model for full machining process of thread milling. Int J Adv Manuf Technol 123, 511–526 (2022). https://doi.org/10.1007/s00170-022-10200-8

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  • DOI: https://doi.org/10.1007/s00170-022-10200-8

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