Prediction of icing interface normal stress response for thin-walled parts machining with ice-based fixturing (IBF)

Abstract

Fixtures can maintain stability in the machining of thin-walled parts (TWP), thus avoiding the occurrence of workpiece deformation. The stress at the fixture-workpiece contact interface is a key factor in evaluating the reliability of the fixture’s restraint on the TWP. This paper investigates the prediction of icing interface normal stress during TWP milling based on the ice-based fixturing (IBF) previously proposed by the authors of this paper. The principle of the IBF is first explained. The mechanical properties of the ice-workpiece bonding material (IWBM) are then characterized by Dundurs parameters. Afterwards, an analytical model for the prediction of icing interface normal stress under cutting load is developed using the Goursat formula based on the interface continuity conditions of stress and displacement. The finite element method (FEM) is then used to verify the accuracy of the prediction model, and the results show that the average prediction error of the icing interface normal stress is limited to 13.99%. Finally, milling experiments are carried out to verify the validity of the finite element model, and the experimental results show that the simulation errors of the main cutting force and feeding force are limited to 12.35% and 11.47% respectively, and the FEM can greatly simulate the cutting state of the workpiece clamped by IBF. This paper can provide a valuable theoretical and practical basis for the analysis and prediction of stress at the workpiece-fixture contact interface.