Predicting the dynamics of thin-walled parts with curved surfaces in milling based on FEM and Taylor series

Wang, Dazhen; Ren, Junxue; Tian, Wenhuai; Shi, Kan; Zhang, Baogang

doi:10.1007/s00170-019-03585-6

Cited by 17 publications

(6 citation statements)

References 22 publications

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“…FEM represents a computationally intensive simulation technique for modeling mechanical and thermal effects during machining such as the calculation of dominant frequencies of thin-walled workpieces based on process specific boundary conditions (Budak et al, 2012;Scippa et al, 2014;Wang et al, 2019). Thin-walled workpieces are usually characterized by natural frequencies in the range of less than 8,000 Hz (Scippa et al, 2014).…”

Section: Finite Element Method-coupled Process Simulations Of Blisk M...mentioning

confidence: 99%

Cloud-based process design in a digital twin framework with integrated and coupled technology models for blisk milling

Rudel¹,

Kienast²,

Vinogradov³

et al. 2022

Front. Manuf. Technol.

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In this publication, the application of an implemented Digital Twin (DT) framework is presented by orchestration of CAM-integrated and containerized technology models carrying out FEM-coupled simulations for the finishing process of a simplified blade integrated disk (blisk) demonstrator. As a case study, the continuous acquisition, processing and usage of virtual process planning and simulation data as well as real machine and sensor data along the value chain is presented. The use case demonstrates the successful application of the underlying DT framework implementation for the prediction of the continuously changing dynamic behavior of the workpiece and according stable spindle speeds in the process planning phase as well as their validation in the actual manufacturing phase.

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Section: Finite Element Method-coupled Process Simulations Of Blisk M...mentioning

confidence: 99%

Cloud-based process design in a digital twin framework with integrated and coupled technology models for blisk milling

Rudel¹,

Kienast²,

Vinogradov³

et al. 2022

Front. Manuf. Technol.

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“…Under the condition of obtaining the sensitivity and setting the eigenvalue level constraints, such as taking the mean sensitivity of the blade as the level reference value, the amount of change in the thickness t of the grid cells can be calculated based on the non-uniform allowance design steps (3)(4)(5) in the finishing stage. The value of the thickness t is obtained by calculation and measurement as follows.…”

Section: Non-uniform Allowance Distribution Of Titanium Alloy Thin-wa...mentioning

confidence: 99%

“…Blades, constituting approximately 30% of the manufacturing process of an aircraft engine, are an essential component with regard to its performance [1][2][3][4][5]. Consequently, CNC precision machining technology has become the primary method for manufacturing blades worldwide.…”

Section: Introductionmentioning

confidence: 99%

Enhancing Chatter Stability for Milling Thin-Walled Blades by Designing Non-Uniform Allowance

Li,

Ding,

Tian

et al. 2023

Applied Sciences

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During the milling of thin-walled blades, the removal of material exhibits strong time-varying dynamics, leading to chatter and a decrease in surface quality. To address the issue of milling vibrations in the machining of complex thin-walled blades used in aerospace applications, this work proposes a process optimization approach involving non-uniform allowances. The objective is to enhance of he stiffness of the thin-walled parts during the milling process by establishing a non-uniform allowance distribution for the finishing process of thin-walled blades. By applying the theory of sensitive process stiffness and conducting finite element simulations, two processing strategies, namely uniform allowances and non-uniform allowances, are evaluated through cutting experiments. The experimental results demonstrate that the non-uniform allowance processing strategy leads to a more evenly distributed acceleration spectrum and a 50% reduction in amplitude. Moreover, the surface exhibits no discernible vibration pattern, resulting in a 35% decrease in roughness. The non-uniform allowance-processing strategy proves to be effective in significantly improving the rigidity of the thin-walled blade processing system, thereby enhancing the stability of the cutting process. These findings hold significant relevance in guiding the machining of typical complex thin-walled aerospace components.

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“…The computational efficiency and memory consumption were efficiently enhanced as the rebuilding of the FE model and re-performing of modal analysis could be avoided. More recently, Wang et al [79] calculated the time-variable dynamics of thin-wall blade structures in the milling process. The mass and stiffness matrices of the initial workpiece and change of the matrices due to material removal were obtained from the FEM model and third-order Taylor series, separately.…”

Section: Prediction Of the Appearance Of Chattermentioning

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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Predicting the dynamics of thin-walled parts with curved surfaces in milling based on FEM and Taylor series

Cited by 17 publications

References 22 publications

Cloud-based process design in a digital twin framework with integrated and coupled technology models for blisk milling

Cloud-based process design in a digital twin framework with integrated and coupled technology models for blisk milling

Enhancing Chatter Stability for Milling Thin-Walled Blades by Designing Non-Uniform Allowance

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

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