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An improved static model for tool deflection in machining of Ti–6Al–4V acetabular shell produced by selective laser melting

Khorasani, Amir Mahyar, Gibson, Ian, Godarzvand Chegini, Nabi, Goldberg, Moshe, Ghasemi, Amir Hossein and Littlefair, Guy 2016, An improved static model for tool deflection in machining of Ti–6Al–4V acetabular shell produced by selective laser melting, Measurement: journal of the International Measurement Confederation, vol. 92, pp. 534-544, doi: 10.1016/j.measurement.2016.06.031.

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Title An improved static model for tool deflection in machining of Ti–6Al–4V acetabular shell produced by selective laser melting
Author(s) Khorasani, Amir Mahyar
Gibson, IanORCID iD for Gibson, Ian orcid.org/0000-0002-4149-9122
Godarzvand Chegini, Nabi
Goldberg, Moshe
Ghasemi, Amir Hossein
Littlefair, Guy
Journal name Measurement: journal of the International Measurement Confederation
Volume number 92
Start page 534
End page 544
Total pages 11
Publisher Elsevier
Place of publication Amsterdam, The Netherlands
Publication date 2016-10
ISSN 0263-2241
Keyword(s) ball nose cutting tool
cutting force
second moment of inertia
static model
tool deflection measurement
Summary Tool deflection during milling operation leads to dimensional error, decreasing surface quality and increasing rejection rate. In this study, tool deflection during the milling of the inner surfaces of Ti–6Al–4V prosthetic acetabular shell produced by selective laser melting (SLM) was modelled. The first purpose of this research is to provide a general static cutting tool deflection model for ball nose cutters where deviation of machine components and tool holder are so small as to be considered negligible. This is because the values of machine component and tool holder deflection were lower than standard tolerances (10 μm) and found to be lower than 1/15 of tool deflection. The second and third objectives of this work involve calculating contact surfaces by determining workpiece and tool geometry and choosing second moment of inertia using a novel cross section method (CSM). Static models for three quasi-analytical methods (QAM) that are simple cantilever beam model (SCBM), two-section model (TWSM) and our three section model (THSM) are presented. THSM showed high accuracy which was validated by 3D finite element method (FEM3D) and experimental measurements. The accuracy of tool deflection calculation using THSM by computing, shank, flute and ball head deflection and also utilizing CSM to determine second moment of inertia showed notable improvements.
Language eng
DOI 10.1016/j.measurement.2016.06.031
Field of Research 010203 Calculus of Variations, Systems Theory and Control Theory
091399 Mechanical Engineering not elsewhere classified
Socio Economic Objective 970109 Expanding Knowledge in Engineering
HERDC Research category C1 Refereed article in a scholarly journal
ERA Research output type C Journal article
Copyright notice ©2016, Elsevier
Persistent URL http://hdl.handle.net/10536/DRO/DU:30085562

Document type: Journal Article
Collection: School of Engineering
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