General Cutting Dynamics Model for Five-Axis Ball-End Milling Operations

Li, Jianhui; Kılıç, Zekai Murat; Altintaş, Yusuf

doi:10.1115/1.4047625

Cited by 39 publications

(14 citation statements)

References 30 publications

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“…As mentioned in the Introduction, it is difficult to determine the engagement region for a general tool and toolworkpiece orientation. A common method (see [51,52]) for determining the engagement conditions is to use a material removal simulation software that generates a matrix of zeros and ones determining whether grid points on the tool surface are in engagement for a discretized tool rotation and blade position. This method was applied in the presented study.…”

Section: Calculation Of Cutting Force and Its Jacobianmentioning

confidence: 99%

Chatter-free milling strategy of a slender Blisk blade via stock distribution optimization and continuous spindle speed change

Petráček

Falta

Stejskal

et al. 2022

Int J Adv Manuf Technol

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The machining process of Blisk blades poses multiple challenges due to high requirements on surface quality and precision combined with high dynamic compliance of the thin-walled blades. Avoidance of chatter is thus of high priority in Blisk blade machining. However, the geometry of the Blisk blade array where the tool must fit between individual blades significantly limits the possibilities of controlling stability through the relative orientation of the tool and workpiece. Thus, the main parameters that can be used to control the stability of the process are the distribution of stock allowance and the spindle speed. Due to the effect of material removal on the blade’s dynamic properties, spindle speed needs to be adjusted throughout the machining process to keep it within the continuously changing stability gaps. This paper describes in detail an optimization procedure for the design of stock allowance distribution in such a way that a continuous spindle speed modulation is possible that avoids chatter throughout the machining process by maintaining spindle speeds within stability gaps. The presented algorithm uses finite element analysis software to simulate the effects of stock allowance distribution and material removal on workpiece dynamical properties. This information is then coupled with a stability model based on the Jacobian of the cutting force with respect to the regenerative deflection to identify the varying stability gaps throughout the machining process. The proposed method was experimentally verified.

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Section: Calculation Of Cutting Force and Its Jacobianmentioning

confidence: 99%

Chatter-free milling strategy of a slender Blisk blade via stock distribution optimization and continuous spindle speed change

Petráček

Falta

Stejskal

et al. 2022

Int J Adv Manuf Technol

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show abstract

“…The geometry description generally follows notation as summed up by Ozturk [23] and Li [16]. This geometry is slightly simplified: the curvature of the machined surface is not considered and the tool-paths are (at least approximately) parallel.…”

Section: Application To Ball-end Millingmentioning

confidence: 99%

“…The coordinate systems used in the analysis respect the notation used by Li [16]. The engagement coordinate system (ECS) is given by the feed direction vector ê F , outer normal vector to the desired surface ê N , and cross-feed direction ê C normal to both, such that ê F , ê C , ê N form a right-handed coordinate system.…”

Section: Coordinate Systemsmentioning

confidence: 99%

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An analytical formulation of ZOA-based machining stability for complex tool geometries: application to 5-axis ball-end milling

Falta

Sulitka

Zeman

2022

Int J Adv Manuf Technol

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The paper describes a computationally convenient analytical formulation of the stability of the cutting process with respect to self-excited vibrations in the case of five-axis milling based on the commonly used zero-order approximation. In the case of five-axis milling with general milling cutters, it is difficult to calculate stable machining process conditions for two main reasons. The first reason is the difficulty of calculating the mean value of the cutting force Jacobian with respect to the regenerative displacement (closely related to a milling directional matrix) for a generally inclined tool, and the second reason is the nonlinearity of this Jacobian with respect to the process parameters, which means that the problem cannot be reduced to a linear eigenvalue problem as is usual for linear cases (e.g. cylindrical milling with respect to the axial depth of cut). In the first part, this paper presents a modification of the calculation of the machining stability limits for a nonlinearly dependent cutting force Jaco-

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“…Currently, several approaches are used to ensure vibration stability of milling [2]: analytical and numerical stability analysis methods [4]- [7], [20]; time integration of equations of motion of the system during milling [8]- [11], [19]; damping of vibrations based on improving individual machine tool parts capable of influencing the dynamic performance of the "tool-part" system as a whole [12], [13]; methods of online detection of chatter using systems with feedback [2], [3].…”

Section: Introductionmentioning

confidence: 99%

Ensuring the chatter stability of milling by optimizing the workpiece stock

Kuts¹,

Kiselev²,

Voronov³

2021

Vib. proced.

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The paper considers a new technique for increasing the dynamic stability of the dynamics of milling flexible parts. The technique is based on the formation of a uniform stock of the workpiece for the finish milling. The paper proposes an optimization algorithm for the automated calculation of the stock distribution based on the sensitivity analysis method. The ratio of the natural frequencies of the flexible workpiece is used as the objective function of the optimization algorithm. The developed technique was tested on a numerical example.

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General Cutting Dynamics Model for Five-Axis Ball-End Milling Operations

Cited by 39 publications

References 30 publications

Chatter-free milling strategy of a slender Blisk blade via stock distribution optimization and continuous spindle speed change

Chatter-free milling strategy of a slender Blisk blade via stock distribution optimization and continuous spindle speed change

An analytical formulation of ZOA-based machining stability for complex tool geometries: application to 5-axis ball-end milling

Ensuring the chatter stability of milling by optimizing the workpiece stock

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