A parametric modeling method for the pose-dependent dynamics of bi-rotary milling head

Du, Chao; Zhang, Jun; Lu, Dun; Zhang, Huijie; Zhao, Wanhua

doi:10.1177/0954405416654599

Cited by 16 publications

(6 citation statements)

References 39 publications

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“…Most papers in the field of transfer machine tools or of multiple-axis automatic machines are focused on modal or dynamic analyses, such as [11,12]. This research trend is also confirmed by a recent study [13] that deals with the development and validation of a multibody dynamic model of a tool-spindle-bearing system, to be incorporated into a five-axis machine with rotary-tilting spindle heads.…”

Section: Introductionmentioning

confidence: 83%

On Hirth Ring Couplings: Design Principles Including the Effect of Friction

et al. 2018

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Rings with Hirth couplings are primarily used for the accurate positioning of axial-symmetric components in the machine tool industry and, generally, in mechanical components. It is also possible to use Hirth rings as connection tools. Specific industries with special milling and grinding machines are able to manufacture both tailor made and standard Hirth rings available on stock. Unfortunately, no international standard (for instance ISO, DIN or AGMA) is available for the production and the design of such components. In the best-case scenario, it is possible to find simplified design formulae in the catalogue of the suppliers. The aim of this work is to provide some accurate formulae and computational methods for design to provide better awareness on the limitations and the potential of this type of connection. The work consists of five parts: (i) a review of the base calculation derived mainly from the catalogues of manufacturers; (ii) an improved calculation based on a new analytical method including the friction phenomenon; (iii) an experimentation run for validating the method; (iv) a case study applied to a machine tool; and, (v) a closed form formulation to determine an upper threshold for friction, thus ensuring the Hirth coupling regular performance.Abstract: Rings with Hirth couplings are primarily used for the accurate positioning of axialsymmetric components in the machine tool industry and, generally, in mechanical components. It is also possible to use Hirth rings as connection tools. Specific industries with special milling and grinding machines are able to manufacture both tailor made and standard Hirth rings available on stock. Unfortunately, no international standard (for instance ISO, DIN or AGMA) is available for the production and the design of such components. In the best-case scenario, it is possible to find simplified design formulae in the catalogue of the suppliers. The aim of this work is to provide some accurate formulae and computational methods for design to provide better awareness on the limitations and the potential of this type of connection. The work consists of five parts: (i) a review of the base calculation derived mainly from the catalogues of manufacturers; (ii) an improved calculation based on a new analytical method including the friction phenomenon; (iii) an experimentation run for validating the method; (iv) a case study applied to a machine tool; and, (v) a closed form formulation to determine an upper threshold for friction, thus ensuring the Hirth coupling regular performance.

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Section: Introductionmentioning

confidence: 83%

On Hirth Ring Couplings: Design Principles Including the Effect of Friction

et al. 2018

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“…A reasonable agreement between measured and calculated stabilities could be achieved. When considering the modeling of pose-dependent dynamics, Du et al [19,20] modeled the dynamic behavior of a bi-rotary milling head using multi-rigid-body dynamic models considering the varying stiffness of the flexible joints affected by gravity and cutting forces. Furthermore, Chao and Altintas [21] optimized the tool path for machining a free-formed surface by analytically analyzing the engagement conditions using FRFs which were measured in different poses.…”

Section: Introductionmentioning

confidence: 99%

Learning-Based Prediction of Pose-Dependent Dynamics

Finkeldey

Wirtz

Merhofe

et al. 2020

JMMP

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The constantly increasing demand for both, higher production output and more complex product geometries, which can only be achieved using five-axis milling processes, requires elaborated analysis approaches to optimize the regarded process. This is especially necessary when the used tool is susceptible to vibrations, which can deteriorate the quality of the machined workpiece surface. The prediction of tool vibrations based on the used NC path and process configuration can be achieved by, e.g., applying geometric physically-based process simulation systems prior to the machining process. However, recent research showed that the dynamic behavior of the system, consisting of the machine tool, the spindle, and the milling tool, can change significantly when using different inclination angles to realize certain machined workpiece shapes. Intermediate dynamic properties have to be interpolated based on measurements due to the impracticality of measuring the frequency response functions for each position and inclination angle that are used along the NC path. This paper presents a learning-based approach to predict the frequency response function for a given pose of the tool center point.

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“…Using this approach, they found that the swivel angel of spindle tool has a greater influence on the variation of frequency and dynamic stiffness of dominant mode as compared to the change of rotational angle. In addition, Du et al [10] presented a multi-rigid-body dynamic model to modeling the bi-rotary milling head at different swing state. In this approach, the structure components, including the rotary shaft, swivel shaft and housing were considered as rigid bodies and the bearings and flexible joints are modeled as elastic spring.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Dynamic Characteristics and Machining Stability of a Bi-rotary Milling Tool

Hung

Lin²

2019

Adv. Sci. Technol. Res. J.

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Bi-rotary milling head is the primary component of multiple-axis machine tool toward the multiply machining operation. The machining performance is greatly related to the structure characteristics and positioning precisions of the swivel head. This study was aimed at developing a bi-rotary milling head module, which is composed of a direct drive motor, cross roller bearings and motorized spindle unit. In order to evaluate the machining stability at the design phase, the dynamic characteristics of the rotary milling were first analyzed with finite element method. Especially, the variations of the dynamic characteristics of the spindle tool with the changing of the titling configuration of swivel axis were examined. In order to consider the accurate presentation of a spindle tool system and swivel mechanism, the bearings in the rolling components were also included in the finite element model and simulated with surface contact elements with adequate contact stiffness. The dynamic frequency response function of the spindle tool at different swinging positions were predicted for comparisons, which were further used to calculate the machining stability based on the machining mechanics. The current results show that the feeding direction and swinging positions of rotary milling head have a significant influence on the dynamic characteristics and machining ability of the spindle tool. The variations of the cutting depth with the swinging of A axis fall in the range of 11% to 40%, depending on the feeding direction and swinging angle. The analysis results are expected to clearly demonstrate the variation of the machining performance of the spindle tool under different milling configurations. The devised model and modeling approach can be applied to develop a five axis milling machine with desired dynamic and machining performance.

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A parametric modeling method for the pose-dependent dynamics of bi-rotary milling head

Cited by 16 publications

References 39 publications

On Hirth Ring Couplings: Design Principles Including the Effect of Friction

On Hirth Ring Couplings: Design Principles Including the Effect of Friction

Learning-Based Prediction of Pose-Dependent Dynamics

Investigation of the Dynamic Characteristics and Machining Stability of a Bi-rotary Milling Tool

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