Double-sided milling of thin-walled parts by dual collaborative parallel kinematic machines

Fu, Rao; Curley, Patrick; Higgins, Colm; Kılıç, Zekai Murat; Sun, Dan; Murphy, Adrian; Jin, Yan

doi:10.1016/j.jmatprotec.2021.117395

Cited by 17 publications

(6 citation statements)

References 35 publications

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“…Mori et al proposed a new method for synchronized milling of exible thin-walled parts with double-sided single teeth, which can offset the milling force by synchronized two-ute milling cutters, and the nal experiments showed that the atness of the processed thin plate was increased by 2 times, and the machining e ciency was increased by 3 times [10]. Fu et al used a double parallel machine tool (PKMS) to achieve synchronous and asynchronous machining and support of thin-walled parts, and the test results showed that the static and dynamic characteristics of the workpieces obtained by double PKMS machining were improved, the dimensional accuracy and surface quality were improved, and the material removal rate was doubled [11]. Mejbel et al developed a double-sided milling cutter co-machining technology, two vertical face milling cutters at the same time machining two thin-walled surfaces, cutting forces offset each other, the test results show that the workpiece atness and straightness are signi cantly increased [12].…”

Section: Introductionmentioning

confidence: 99%

Research on the Dynamic Flexible Support Machining Method for Propeller Blades

Li,

Wang,

et al. 2024

Preprint

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At present, most of the propeller machining adopts single-sided machining, and its machining vibration and deformation seriously affect the machining accuracy. To reduce the machining vibration, a dynamic flexible support machining method is proposed, i.e., while the tool is machining, the multi-point flexible support device supports the blade and counteracts the milling force to suppress the vibration and deformation. Due to the complex shape of the blade and the special structure of the support device, the blade is divided into different areas, and a support motion trajectory combining symmetric and asymmetric motions is planned, and then a set of post-processing systems is introduced. After obtaining the tool position points, the support points are solved cyclically by the ergodic method. Subsequently, the support points are interpolated, and the vectors are smoothed to obtain smooth and continuous support trajectories. Finally, the machining parameters are calculated, and the machining data applicable to the XYZ-3RPS hybrid machine are integrated. The feasibility of the proposed support trajectory and post-processing algorithm was ultimately demonstrated through practical machining experiments.

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Section: Introductionmentioning

confidence: 99%

Research on the Dynamic Flexible Support Machining Method for Propeller Blades

Li,

Wang,

et al. 2024

Preprint

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“…The downsides of using these methods include significant development and operational costs, as well as limited versatility to handle varied geometries within a family of parts. Modern tendencies in large thin-walled components are looking at single setup environments which can allow unrestricted access to the workpiece on both sides [1], referred to as double sided access (dsa), schematic shown in Figure 1. The main challenge arising from this ambitious type of setup is an increase in machining induced vibrations issues due to the inherent reduction in workpiece stiffness.…”

Section: Introductionmentioning

confidence: 99%

Unsupported machining fixture layout optimisation

Soto,

Sims,

Ozturk

et al. 2024

J. Phys.: Conf. Ser.

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It is well established that excessive vibrations in machining operations hinder productivity and quality of the components being made. In these environments it is common to encounter self-excited vibrations due to the dynamic response characteristics of the cutting tool and workpiece; referred to as regenerative chatter. To suppress these effects, conventional practices provide the workpiece with as much support as possible and therefore commonly require custom-built fixturing bases and several manual intervention stages. In contrast, for modern reduced fixturing approaches, the workpiece is minimally-held, with the benefits of reduced setup times, lower fixturing and inventory costs, and improved access to the workpiece thereby avoiding multi-stage setups. However, minimal fixturing reduces support of the workpiece, and so vibration becomes a greater challenge, along with the subsequent detrimental effects to part quality and material removal rate (mrr). This paper sets out to determine an optimisation methodology for layout configurations that maximise milling depths of cut whilst achieving dynamic stability; by means of FEA model-based simulations and particle swarm optimisation (pso) methods. The optimisation algorithm is then tested on simplified setups and compared to exhaustive searches. It is shown that optimal results can differ from standard practice, and despite the comparative reduction in workpiece stiffness to a traditional approach is mostly unavoidable, careful placement of workholding elements can reportedly improve cutting conditions and increase dynamic stability within an unsupported environment.

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“…This investigation solves the shortcomings in traditional single-sided machining of propellers by means of double-sided machining. In recent years, academia has produced a profound study on the theory of double-sided machining [3][4][5][6][7][8][9][10][11][12][13][14][15]. Mohanad Kadhim Mejbel, Isam Tareq Abdullah, et al have studied the simultaneous machining of thinwalled surfaces with double-end cutter milling, which greatly improves the flatness and straightness of the workpiece surface [3].…”

Section: Introductionmentioning

confidence: 99%

Investigation on Tool Path Planning Algorithm of Propeller Blade Double-Sided Collaborative Machining

Wang

Guo

2023

Applied Sciences

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The concomitant vibration and deformation produced by propeller blades in single-sided machining seriously affect the surface machining precision. Double-sided symmetrical machining can improve system rigidity through mutual shoring on both sides which abates the concomitant vibration and deformation. However, the actual double-sided symmetrical machining cannot be applied to blade machining due to its shape complexity. The double-sided collaborative machining method combining symmetrical machining and staggered machining is devised in this paper, and its tool path planning algorithm is investigated. Firstly, the algorithm achieves smooth fitting and correspondence of bilateral cutter position points through double-curve interpolation and position data alignment. Secondly, the blade surface is divided into four regions by two partition parameters: tip region, internal region, variable region, and edge region. Then, the conversion between symmetrical machining and staggered machining is completed through the Sigmoid deformation curve in the variable region. Finally, the feasibility and superiority of double-sided collaborative machining are verified through machining experiments.

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Double-sided milling of thin-walled parts by dual collaborative parallel kinematic machines

Cited by 17 publications

References 35 publications

Research on the Dynamic Flexible Support Machining Method for Propeller Blades

Research on the Dynamic Flexible Support Machining Method for Propeller Blades

Unsupported machining fixture layout optimisation

Investigation on Tool Path Planning Algorithm of Propeller Blade Double-Sided Collaborative Machining

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