Determination of Diametral Error Using Finite Elements and Experimental Method

Many manufacturing defects could be seen in cylindrical turning. Some of these defects are: elastic deformation of work-piece, nonlinear backlash of cutting set – machine – workpiece, unknown geometry of untreated part, thermal deformations, vibration of set and machine. Deflection of workpiece under cutting forces will cause different levels of processing of workpiece 1 . Nonlinear backlash of cut-ting set – machine – workpiece will cause elastic deformation in structures of fasteners and machine 1, 2 . Friction occurred while abrasive machining and heat generated by plastic deformation alters geometry of cutting 3 . Cutting forces influence error estimations. In numerical examples formed along the workpiece axis in order to estimate cutting forces and diametral errors, cutting conditions affect manufacturing process. Most essential of these is corrosion of set which changes geometry of set 4, 5 . Another one is vibration which occurs amongst cutting set–machine–workpiece final form of workpiece in cylindrical turning will not conserve the diameter it had at the beginning of the process due to deflection of workpiece due to cutting forces 6 . A developed processing method is required in order to achieve higher exactitude in diameter measurements of workpiece after turning. Computer assisted error correction systems are developed to achieve higher exactitude in turning process 7, 8 . In this study, diametral error occurred during turning process of a cylindrical piece has been theoretically and experimentally analyzed. Finite element method is applied on workpiece which is one end bound.