Simulation of workpiece deformation caused by machining and clamping forces

Simulating technological processes offer the chance to optimize machining strategy, tool selection and machining parameters in early development stages and allow to analyze relationships between component design, machining processes and product quality. An important prerequisite for a comprehensive simulation of metalcutting processes is the consideration of mechanically and thermally induced workpiece deformation during machining. If processing deformations are known, the resulting deviations of dimensions and shape may be compensated in order to keep the required tolerances. It is even possible to reduce deformations from the outset by design. The paper shows the application of finite element method (FEM) simulation calculations of workpiece deformation during process simulation of a complex component. Both clamping and machining forces are taken into account. Simulation results and measurements tally quite well.