Relative Varying Dynamics Based Whole Cutting Process Optimization for Thin-walled Parts

Abstract

Thin-walled parts are typically difficult-to-cut components due to the complex dynamics in cutting process. The dynamics is variant for part during machining, but invariant for machine tool. The variation of the relative dynamics results in the difference of cutting stage division and cutting parameter selection. This paper develops a novel method for whole cutting process optimization based on the relative varying dynamic characteristic of machining system. A new strategy to distinguish cutting stages depending on the dominated dynamics during machining process is proposed, and a thickness-dependent model to predict the dynamics of part is developed. Optimal cutting parameters change with stages, which can be divided by the critical thickness of part. Based on the dynamics comparison between machine tool and thickness-varying part, the critical thicknesses are predicted by an iterative algorithm. The proposed method is validated by the machining of three benchmarks. Good agreements have been obtained between prediction and experimental results in terms of stages identification, meanwhile, the optimized parameters perform well during the whole cutting process.

Multiple Response Prediction and Optimization in Thin-Walled Milling of 6061 Aluminum Alloy

“…Thin-walled products are often difficult to cut due to the complex dynamics involved. During the cutting process, the cutting dynamics for the products varies however it is invariant for the machine tool [8]. On another hand, permanent deformation of the structure can occur and this can cause a proportion of rejected products [9].…”

“…This can be solved through experimentation [12,13], or mathematical modelling [14]. Authors in [8] present a methodology of performing the optimization of the entire cutting process for thin-walled parts based on the relatively changing kinematics of the machining system. According to the comparison between the dynamics of the machine tool and the variable thickness part, the critical thickness is investigated by an iterative algorithm.…”