Dynamic modeling and stability prediction in milling process of thin-walled workpiece with multiple structural modes

Zhang, Zhao; Luo, Ming; Wu, Baohai; Zhang, Dinghua

doi:10.1177/0954405420933710

Cited by 13 publications

(8 citation statements)

References 24 publications

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“…where r m is the radius, M is the magnetization of the cylindrical magnet, dz 0 is the thickness of the molecular current, and m 0 is permeability of vacuum. For a magnet with height h, the magnetic induction intensity B is induced and its components are formulated as equation (6).…”

Section: Eddy Current Dampingmentioning

confidence: 99%

“…Liu et al 5 proposed a tool inclination method based on the adoption of the cutting force component in the lowest stiffness direction of the thin-walled part to guarantee the machined surface finish. Zhang et al 6 developed a complete dynamic model of thin-walled part milling system including multiple structural modes, and achieved the stability lobs by numerical integration. However, available selection of cutting parameters could be restricted due to low stability limit of thin-walled part, and the active or passive vibration control could be indeed powerful in this case.…”

Section: Introductionmentioning

confidence: 99%

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Design of a composite viscous damper and application on cylindrical thin-walled part milling

Chen

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Chatter vibration is apt to occur when machining thin-walled parts with insufficient rigidity. The harmful excitation of periodical cutting forces can be mitigated by enhancing the dynamic stiffness or increasing the damping of the part. A composite viscous damper including air damping and eddy current damping is designed, which can be attached on the thin-walled part by the vacuum. Based on the formulations of air damping and eddy current damping, the optimal equivalent viscous damping is derived for achieving the maximum critical depth of cut. Furthermore, the geometries of the damper are determined for damping a specific thin-walled part after investigating its relationship with viscous damping. The modal test indicates that the damper can suppress multiple modes of the cylindrical thin-walled part, and the amplitude of the first mode of the frequency response function (FRF) is reduced by 57%. The composite viscous damper is applied to suppress the chatter and resonant vibration of the thin-walled part during machining. Milling tests demonstrate that the machining vibration is reduced by 55% and 76% after employing single damper and four dampers, respectively.

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Section: Eddy Current Dampingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Design of a composite viscous damper and application on cylindrical thin-walled part milling

Chen

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Especially, cutting parameter optimization through the stability lobes is an efficient method and has been widely employed in the industry. 3 The chatter stability prediction based on linear model achieves high accuracy for most cases. However, nonlinearities have been evidenced during the milling process.…”

Section: Introductionmentioning

confidence: 99%

“…Especially, cutting parameter optimization through the stability lobes is an efficient method and has been widely employed in the industry. 3…”

Section: Introductionmentioning

confidence: 99%

Chatter stability prediction of milling considering nonlinearities

Yang

Liu

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Nonlinearities have been evidenced during the chatter vibration of milling. Machinability of the thin-walled part is feed rate and position-dependent, and is subject to process damping at low cutting speed. Therefore, chatter stability prediction of milling considering nonlinear cutting force, nonlinear structural stiffness and process damping is investigated. The cutting force and stiffness are established based on the polynomial model and the process damping is investigated based on the dissipated energy. The dynamic cutting force and stability lobes are solved in the time domain with coefficients updated at each iteration. By formulating the displacement as an expanded form via the perturbation method, the time-consuming solution of delay differential equations is avoided. After formulating the identification of the nonlinear model via cutting tests and modal tests, numerical simulations considering nonlinearities are carried out and compared with the analytical method. The proposed method attains high accuracy of classic time-domain solution, but with an improved computational efficiency. Finally, cutting tests are conducted to verify the prediction of cutting force and stability lobes.

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“…In order to better determine the state of the workpiece surface, Miao et al 27 analyzed the influence of machining parameters on specific materials in machining. Zhang et al 28 established a complete dynamic model of thin-walled workpiece milling system. Duan et al 29 summarized the research progress of cutting force model and determined the problem of cutting force modeling.…”

Section: Introductionmentioning

confidence: 99%

Effect of temperature on milling stability of thin-walled parts

Liu

Cui

Chen

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Milling, as a common machining method, is widely used in rough machining and final finishing of various materials. In this paper, according to the milling temperature produced in the milling process, the formula of heat distribution coefficient for workpiece milling is established. By means of Deform-3D finite element software to carry out orthogonal cutting simulation of workpiece, the influence of different machining parameters on milling heat distribution coefficient is studied, the optimal machining parameters are determined, and the milling temperature experiment is carried out to verify the simulation temperature. The experimental results show that the simulation temperature is very close to the experimental workpiece temperature, and the error is very small, which verifies the accuracy of the method. At the same time, the influence of different initial temperature of workpiece on the milling force and stability is also studied. The results show that proper heating of the workpiece can effectively improve the milling stability of the thin-walled parts.

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Dynamic modeling and stability prediction in milling process of thin-walled workpiece with multiple structural modes

Cited by 13 publications

References 24 publications

Design of a composite viscous damper and application on cylindrical thin-walled part milling

Design of a composite viscous damper and application on cylindrical thin-walled part milling

Chatter stability prediction of milling considering nonlinearities

Effect of temperature on milling stability of thin-walled parts

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