Numerical simulation and experimental investigation of structured surface generated by 3D vibration-assisted milling

Lv, Bingrui; Lin, Bin; Cao, Zhongchen; Liu, Wenrui; Wang, Guilian

doi:10.1016/j.jmapro.2023.01.010

Cited by 9 publications

(3 citation statements)

References 31 publications

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“…The spindle was not considered in this model. The micro-milling method, assisted by a three-dimensional vibration, was proposed by Lv et al [29]. The resulting shape of the structures was predicted by numerical software and compared with experimental data.…”

Section: Ball End Millingmentioning

confidence: 99%

A Numerical Analysis for Ball End Milling Due to Coupling Effects of a Flexible Rotor-Bearing System Using GPEM

Huang

Chang²,

Shiau

et al. 2023

Applied Sciences

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In this paper, the tool-tip responses for ball end milling, due to the coupling effects of a flexible rotor-bearing system, are investigated numerically. The milling machine tool spindle is modelled as the flexible rotor-bearing system. The critical speeds, natural modes, and unbalance responses of the system are calculated by applying the generalized polynomial expansion method. This generalized polynomial expansion method expresses the displacement as a series formed by the product of generalized coordinates and axial coordinate polynomials. According to the dynamic cutting force obtained by some scholars in the past, combined with the characteristics of the flexible rotor, the dynamic response of the tool-tip for ball end milling is numerically analyzed. The responses, including time histories, orbits, and FFT diagrams, are plotted to analyze the dynamic behaviors of the tool-tip. The coupling effects of the flexible rotor-bearing system on the system for ball end milling are first studied using the generalized polynomial expansion method. Unlike previous studies, the natural frequency varies with spindle speed and which of the different modes are included in the tool-tip response depends mainly on the spindle speed. Thanks to the gyroscopic effect, the critical speeds and responses of tool-tips can be discussed with respect to various spindle speed and tool flutes. The natural modes are accurately determined, and will excite critical speeds for certain modes, including forward and backward modes, thereby significantly affecting tool-tip response. In addition, the cutting force component associated with the tool-tip response affects the rotor-bearing system parameters, complicating the issue. Milling at higher spindle speed (2160–19,950 rpm), an important new result is found that the tool-tip oscillates with the cutting-force frequency, accompanied by a longer period vibration of the first backward mode of the rotor-bearing system. It can also be seen from the frequency spectrum analysis that, as the spindle speed increases, the peak amplitude of the first backward mode becomes larger. Milling at lower spindle speed (960, 1320 rpm), the in-plane vibration trajectory of the tool-tip gradually expands outwards clockwise around the origin until a stable loop is reached. This is because only the first backward mode of the rotor-bearing system is excited. Considering the coupling effect of the rotor-bearing system to perform the vibration analysis of the milling machine system, the parameters of the system can be designed or the spindle speed can be selected to avoid severe vibration during machining.

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Section: Ball End Millingmentioning

confidence: 99%

A Numerical Analysis for Ball End Milling Due to Coupling Effects of a Flexible Rotor-Bearing System Using GPEM

Huang

Chang²,

Shiau

et al. 2023

Applied Sciences

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“…In 3D surface texture modeling, Chen et al [ 27 , 28 ] proposed a model based on homogenous matrices transformation, establishing the surface profile according to the tool tip’s shape. Lv et al [ 29 ] developed a 3D vibration-assisted milling model for generating various structured surfaces by employing orthogonal spiral and multi-body kinematics theories. Yuan et al [ 30 ] presented a vibration-assisted ball-end milling method for generating various surface textures using a non-resonant vibrator.…”

Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

Song,

Zhang,

Jing

et al. 2024

Micromachines

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Vibration-assisted micro milling is a promising technique for fabricating engineered mi-cro-scaled surface textures. This paper presents a novel approach for theoretical modeling of three-dimensional (3D) surface textures produced by vibration-assisted micro milling. The proposed model considers the effects of tool edge geometry, minimum uncut chip thickness (MUCT), and material elastic recovery. The surface texture formation under different machining parameters is simulated and analyzed through mathematical modeling. Two typical surface morphologies can be generated: wave-type and fish scale-type textures, depending on the phase difference between tool paths. A 2-degrees-of-freedom (2-DOF) vibration stage is also developed to provide vibration along the feed and cross-feed directions during micro-milling process. Micro-milling experiments on copper were carried out to verify the ability to fabricate controlled surface textures using the vibration stage. The simulated and experimentally generated surfaces show good agreement in geometry and dimensions. This work provides an accurate analytical model for vibration-assisted micro-milling surface generation and demonstrates its feasibility for efficient, flexible texturing.

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“…Wan et al [9] investigated a theoretical approach to predict micromilling forces by incorporating the effect of tool deflection on the process. The 3D vibration-assisted milling model developed by considering the theory of orthogonal helical and multi-body kinematics [10]. The cutting force component depended on the geometry of the cutting edge and the grip conditions [11].…”

Section: Introductionmentioning

confidence: 99%

The simulation and experimentation of spiral flat bottom engraving

Chen,

You

2023

J. Phys.: Conf. Ser.

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The study uses rigid-plastic finite element (FE) DEFORM TM 3D software to investigate the plastic deformation behaviour of spiral flat bottom engraving. The finite element analysis assumes that the spiral flat bottom is a rigid body. During the engraving process, the deformation causes an increase in temperature and wear inside the blank. The FE analyses investigate the effects of cutting speed, depth of cut, and the feed of the workpiece on the damage, effective strain, stress, temperature, and wear induced within the workpiece. The simulation results confirm the suitability of the DEFORM TM 3D software for modelling the spiral flat bottom engraving. Comparisons of engraving of spiral flat bottom with clockwise and counter-clockwise have been performed. The analysis of following stress-strain simulation has been predicted by machine learning in this study. Eventually, the experiment of spiral flat bottom engraving is used.

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Numerical simulation and experimental investigation of structured surface generated by 3D vibration-assisted milling

Cited by 9 publications

References 31 publications

A Numerical Analysis for Ball End Milling Due to Coupling Effects of a Flexible Rotor-Bearing System Using GPEM

A Numerical Analysis for Ball End Milling Due to Coupling Effects of a Flexible Rotor-Bearing System Using GPEM

Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

The simulation and experimentation of spiral flat bottom engraving

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