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A High Fidelity Prototype to Predict the Machined Surface Quality Defects due to Workpiece & Tool Vibrations during Face Milling Operations

In the race for productivity, French manufacturers encounter many difficulties in controlling machining processes, particularly on parts that deform and vibrate significantly during machining. These phenomena pose major problems of non-conformity because very often the topographical quality of the machined surfaces is insufficient and does not meet the needs demanded by the design offices or the customers.

 

It is true, especially, in the automotive Industry Sector, where OEMs are facing a tedious challenge with the Machining of all the new Electric Powerstrain Metallic Components

Some toolmakers use numerical simulation which already gives them productivity gains on specific problems, but they only provide a partial response to real needs. It is a major challenge today to develop innovative solutions based on more sophisticated physical models. It is an objective in line with the strategy of major groups, whose ambition is now to completely virtualize the manufacturing and design chain for high value-added parts.

In this context, the Nessy2M research software (PIMM Laboratory), thanks to its transitional dynamic approach fits exactly to this new market demand for predicting of the ondulations, roughness and the deviations of shape on the machined surfaces in the presence of deformations or vibrations.

 Through the  IMPULSA and the SINUSOIDE Co-financed projects ESI  and with the help of 7 industrial partners,  has accelerated the industrialization of this innovative digital simulation technology. Thanks to this new unique approach, delivery times can be drastically reduced, and significant productivity gains can be realized.

Final Machined Surface Roughness for a Titanium Based Component  Courtesy of SAFRAN

ESI will be present during INTERCUT 2020. Please don’t hesitate to meet us for live demo on our booth.

Key Contacts

Gilles  CROISONNIER ( )  currently in charge of Innovation and Discovery for the Machining Domain,. After joining ESI Group in 1997, Gilles held several positions, from technical support management, to project management, and business developments  on a variety of manufacturing products. Previously, Gilles worked as an application engineer for FRAMATOME and RENAULT account. Gilles graduated from the INSA Lyon in France with a background in  Mechanical engineering

Pr. Philippe Lorong  ( ) is an expert in modeling dynamics for Machining System. He is currently heading the Dysco Research Group (Dynamic Structures Systems and Control) of the PIMM Lab.  Philippe is managing the Nessy2M development team that powers the ESI Machining Solution. Philippe has been teaching FE theory to student engineers and scientists in Mechanics at Ecole Nationale d'Arts et Metiers since 2008. He has published two books & 25 international articles and cumulates more than 30 PhD Jury participation.