Chatter stability prediction in four-axis milling of aero-engine casings with bull-nose end mill

Zhou, Xing; Zhang, Dinghua; Luo, Ming; Wu, Baohai

doi:10.1016/j.cja.2015.06.001

Cited by 33 publications

(11 citation statements)

References 18 publications

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“…For thin-walled workpiece, the cutter is regarded as rigidity compared to workpiece. Considering the workpiece geometry and tool path in milling of thin-walled parts, several experiments shows that the vibration in Z direction is the dominant mode compared with that in X, Y directions, which can be verified by Zhou et al [30]. Hence, for simplification, the dynamic milling forces in X and Y directions can be ignored.…”

Section: Dynamic Characteristics Reconstruction Strategymentioning

confidence: 79%

Dynamic characteristics reconfiguration of fixture-workpiece system for vibration suppression in milling of thin-walled workpieces based on MR damping fixture

Li²,

Zhang³

et al. 2022

Preprint

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Milling of the low rigidity and large deformation thin-walled workpiece is a critical challenging task due to the obvious machining vibration, which greatly affects the machining accuracy, surface quality of the final part. Compared with the conventional methods, this paper focuses on suppressing the machining vibration of the flexible workpiece by the MR damping fixture. A novel dynamic characteristics reconstruction strategy of MR damping fixture-workpiece system is proposed to improve the system dynamic characteristics of milling system considering the effect of material removal. Then, the fixture-workpiece system dynamic characteristics reconstruction model is established, in process, the time-varying modal parameters in different conditions are iteratively identified and the stable depth of cut is obtained in any moment. Based on this, the control currents of MR damping fixture are calculated to offset the change of the damping and stiffness properties of the milling system caused by material removal. Subsequently, the feasibility and effectiveness of the proposed method are validated by several experiments. Experimental results show that compared with the initial machining state, the dynamic properties of the fixture-workpiece system are reconstructed by the MR damping fixture, and the vibration response is reduced by 30%~70% and the machined surface is improved effectively.

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Section: Dynamic Characteristics Reconstruction Strategymentioning

confidence: 79%

Dynamic characteristics reconfiguration of fixture-workpiece system for vibration suppression in milling of thin-walled workpieces based on MR damping fixture

Li²,

Zhang³

et al. 2022

Preprint

Self Cite

View full text Add to dashboard Cite

show abstract

“…Except for these commonly-used methods, the optimization of tool orientation, machining procedure was also investigated in previous studies for chatter suppression [175][176][177]. Alan et al [178] applied the structural modification method to obtain the FRFs at different machining stages and optimized the cutting strategy to increase the chatter-free MRR.…”

Section: Active Chatter Control Strategiesmentioning

confidence: 99%

A state-of-art review on chatter and geometric errors in thin-wall machining processes

Pan

et al. 2021

Journal of Manufacturing Processes

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“…Self-excited vibrations dapat dihentikan dengan memberikan variasi pada tooth passing frequency sehingga fase chip load tidak out of phase dan regenerative effect dari sistem tidak terjadi. (Zhou, Zhang, Luo, & Wu, 2015) melakukan penelitian tentang chatter stability prediction menggunakan mesin milling 4 axis pada material alluminium alloy untuk aero-engine casings, eksperimen tersebut menggunakan pahat bull nosed-endmill. Penelitian tersebut menggunakan stability lobe diagram sehingga mendapatkan spindle speed dan radial depth of cut yang ideal untuk mengidentifasi chatter dalam proses permesinan.…”

Section: A R T I C L E I N F O a B S T R A C Kunclassified

Pengaruh Geometri Pahat Variabel Helix Angle Pada Parameter Mesin Cnc Milling Vertikal Berbasis Mikrokontroler Terhadap Nilai Getaran Chatter

Hardinsi

Novareza

Sonief

2020

jami

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Abstrak Objektif. Getaran yang sering terjadi pada pengerjaan proses produksi menggunakan permesinan CNC milling merupakan hal yang sangat penting untuk diperhitungkan. Getaran ini dapat menyebabkan perubahan dimensi dan mempengaruhi tingkat kualitas benda kerja yang dihasilkan, sehingga efek getaran chatter atau self-excited vibration pada proses pengerjaan produksi menjadi masalah utama dalam proses permesinan milling. Nilai getaran chatter ditentukan menggunakan grafik SLD secara ekperimental untuk mengetahui batas antara chatter free dan chatter occurs. Material and Metode. Material yang digunakan dalam penelitian ini adalah Stanless steel 304, dengan menggunakan sensor MPU 6050 yang terhubung pada mikrokontroler Arduino Uno menggunakan software LabVIEW 2019 student edition yang digunakan untuk mengidentifikasi nilai acceleration getaran chatter. Besar nilai acceleration diukur menggunakan FFT menggunakan software DIAdem 2019 student. Metode yang digunakan dalam penelitian ini adalah dalam bentuk eksperimental, dengan geometri pahat Variabel Helix Angle (VHA) 2 variasi sudut yaitu 40/42 (Derajat), Spindel Speed sebesar 2000,2500,3000 (RPM) , Axial Depth Of Cut sebesar 0.5, 1.0, 1.5 (mm), dan Feed Rate sebesar 100, 125 dan 150 (mm/s). Hasil. Hasil pada Grafik Stability Lobe Diagram yang didapatkan pada proses permesinan slot milling menggunakan pahat variable helix angle 40/42 derajat dengan feed rate 150 mm/mnt memiliki chatter free yang lebih tinggi dibandingkan dengan feed rate 100 dan 125 mm/mnt. Kesimpulan. Dari hasil yang didapatkan bahwa semakin tinggi nilai feed rate maka nilai acceleration getaran chatter semakin rendah. Untuk pengembangan dalam penelitian selanjutkan maka perlu dilakukan pemilihan parameter geometri pahat dengan variasi 3 sudut mata pahat untuk mengetahui nilai getaran chatter yang signifikan. Abstrack Objective.Vibration that often occurs in the production process using CNC milling is very important to be taken into account. This is vibration can cause dimensional changes and affect the level of quality of the workpiece produced. Therefore, effect of chatter vibration or self-excited vibration on production process becomes a major problem in the milling machining process. Chatter vibration values can be determined using experimental SLD for determine boundary between free chatter and chatter occur. Materials and Methods .The material used in this study is stanless steel 304, using the MPU 6050 sensor connected to Arduino Uno mikrokontroler using LabVIEW 2019 student edition software that is used to identify chatter vibration acceleration. Acceleration is measured using FFT using 2019 student DIAdem software. The method used is experimental, geometry Variable Helix Angle 2 angular 40/42 (Degrees), Spindel Speed of 2000,2500,3000 (RPM), Axial Depth Of Cut of 0.5, 1.0, 1.5 (mm), and Feed Rate of 100, 125 and 150 (mm / s). Results. Results in the Graph Lobe Stability Diagram obtained in slot milling machining process using a variable helix angle of 40/42 degrees with feed rate of 150 mm / min have higher chatter free compared to feed rates of 100 and 125 mm / min. Conclusion. The results show that higher the value of feed rate, chatter vibration acceleration value is lower. For further development in research, it is necessary to select tool geometry parameters with variations of 3 tool eye angle to determine chatter vibration significant

show abstract

Chatter stability prediction in four-axis milling of aero-engine casings with bull-nose end mill

Cited by 33 publications

References 18 publications

Dynamic characteristics reconfiguration of fixture-workpiece system for vibration suppression in milling of thin-walled workpieces based on MR damping fixture

Dynamic characteristics reconfiguration of fixture-workpiece system for vibration suppression in milling of thin-walled workpieces based on MR damping fixture

A state-of-art review on chatter and geometric errors in thin-wall machining processes

Pengaruh Geometri Pahat Variabel Helix Angle Pada Parameter Mesin Cnc Milling Vertikal Berbasis Mikrokontroler Terhadap Nilai Getaran Chatter

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