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Research on tool wear and compensation to improve contour accuracy in precision machining of thin-walled curved components.

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Title: Research on tool wear and compensation to improve contour accuracy in precision machining of thin-walled curved components.
Authors: Wang, Dong1,2 (AUTHOR), Wei, Zhaocheng1 (AUTHOR), Chen, Yu2 (AUTHOR), Ding, Xiangzhou1,2 (AUTHOR), Huang, Ming2 (AUTHOR) hmhy1972@163.com, Li, Jiasheng2 (AUTHOR) neujsli@163.com
Source: International Journal of Advanced Manufacturing Technology. Jan2026, Vol. 142 Issue 1/2, p475-492. 18p.
Subjects: Spherical shells (Engineering), Machining, Mechanical abrasion, Thin-walled structures, Curvature measurements
Abstract: The thin-walled spherical shell made from 45# steel is a crucial component in high-end equipment fields such as precision physical experiments, aerospace, and national defense. Tool wear is a key factor that determines the high contour accuracy of these spherical shells. During the precision machining of spherical shells, the cutting edge radius (rn​) and the cutting depth (ap) are of comparable magnitudes, making the cutting depth highly sensitive to changes in the cutting edge radius. Furthermore, as the tool-workpiece contact (TWC) zone continuously changes, the tool wear under this working condition is more complex. This paper takes the 45# steel thin-walled spherical shell as the research object, aiming to study the tool wear characteristics when rn​≈ap. We also explore tool wear compensation methods to improve the contour accuracy of the spherical shell. Based on the relationship between rn​ and ap, we analyze the chip formation mechanisms in precision cutting and develop a TWC movement model during shell machining, which enables the prediction of the shape of tool wear bands. Furthermore, we conduct tool wear experiments to validate the accuracy of the model. Through a quantitative analysis of the relationship between cutting edge degradation and machining errors, we ascertain that tool wear contributes approximately 40% to the machining error. Additionally, we propose a compensation method for tool wear in the precision machining of thin-walled spherical shells based on the maximum degradation of the cutting edge. Experimental results demonstrate that this compensation method can effectively improve machining accuracy by approximately 50%. This study provides actionable insights and a theoretical foundation for high-performance manufacturing processes of thin-walled curved components at the tool wear level, demonstrating significant engineering application value. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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Header DbId: egs
DbLabel: Engineering Source
An: 190749993
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
PreciseRelevancyScore: 0
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Items – Name: Title
  Label: Title
  Group: Ti
  Data: Research on tool wear and compensation to improve contour accuracy in precision machining of thin-walled curved components.
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  Data: <searchLink fieldCode="AR" term="%22Wang%2C+Dong%22">Wang, Dong</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wei%2C+Zhaocheng%22">Wei, Zhaocheng</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Chen%2C+Yu%22">Chen, Yu</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Ding%2C+Xiangzhou%22">Ding, Xiangzhou</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Huang%2C+Ming%22">Huang, Ming</searchLink><relatesTo>2</relatesTo> (AUTHOR)<i> hmhy1972@163.com</i><br /><searchLink fieldCode="AR" term="%22Li%2C+Jiasheng%22">Li, Jiasheng</searchLink><relatesTo>2</relatesTo> (AUTHOR)<i> neujsli@163.com</i>
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Jan2026, Vol. 142 Issue 1/2, p475-492. 18p.
– Name: Subject
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  Data: <searchLink fieldCode="DE" term="%22Spherical+shells+%28Engineering%29%22">Spherical shells (Engineering)</searchLink><br /><searchLink fieldCode="DE" term="%22Machining%22">Machining</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+abrasion%22">Mechanical abrasion</searchLink><br /><searchLink fieldCode="DE" term="%22Thin-walled+structures%22">Thin-walled structures</searchLink><br /><searchLink fieldCode="DE" term="%22Curvature+measurements%22">Curvature measurements</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: The thin-walled spherical shell made from 45# steel is a crucial component in high-end equipment fields such as precision physical experiments, aerospace, and national defense. Tool wear is a key factor that determines the high contour accuracy of these spherical shells. During the precision machining of spherical shells, the cutting edge radius (rn​) and the cutting depth (ap) are of comparable magnitudes, making the cutting depth highly sensitive to changes in the cutting edge radius. Furthermore, as the tool-workpiece contact (TWC) zone continuously changes, the tool wear under this working condition is more complex. This paper takes the 45# steel thin-walled spherical shell as the research object, aiming to study the tool wear characteristics when rn​≈ap. We also explore tool wear compensation methods to improve the contour accuracy of the spherical shell. Based on the relationship between rn​ and ap, we analyze the chip formation mechanisms in precision cutting and develop a TWC movement model during shell machining, which enables the prediction of the shape of tool wear bands. Furthermore, we conduct tool wear experiments to validate the accuracy of the model. Through a quantitative analysis of the relationship between cutting edge degradation and machining errors, we ascertain that tool wear contributes approximately 40% to the machining error. Additionally, we propose a compensation method for tool wear in the precision machining of thin-walled spherical shells based on the maximum degradation of the cutting edge. Experimental results demonstrate that this compensation method can effectively improve machining accuracy by approximately 50%. This study provides actionable insights and a theoretical foundation for high-performance manufacturing processes of thin-walled curved components at the tool wear level, demonstrating significant engineering application value. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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      – Type: doi
        Value: 10.1007/s00170-025-17066-6
    Languages:
      – Code: eng
        Text: English
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      Pagination:
        PageCount: 18
        StartPage: 475
    Subjects:
      – SubjectFull: Spherical shells (Engineering)
        Type: general
      – SubjectFull: Machining
        Type: general
      – SubjectFull: Mechanical abrasion
        Type: general
      – SubjectFull: Thin-walled structures
        Type: general
      – SubjectFull: Curvature measurements
        Type: general
    Titles:
      – TitleFull: Research on tool wear and compensation to improve contour accuracy in precision machining of thin-walled curved components.
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            NameFull: Wang, Dong
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            NameFull: Wei, Zhaocheng
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            NameFull: Chen, Yu
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            NameFull: Ding, Xiangzhou
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            NameFull: Huang, Ming
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            NameFull: Li, Jiasheng
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            – D: 01
              M: 01
              Text: Jan2026
              Type: published
              Y: 2026
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              Value: 142
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              Value: 1/2
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            – TitleFull: International Journal of Advanced Manufacturing Technology
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