The experimental study on interaction of vibration and dynamic force in precision milling process

Abstract

A good understanding of the dynamic characteristic in milling of aerospace aluminum, especially the coupling vibration caused by the interaction of the manufacturing process and the machine tool, helps promote the machining precision and surface quality of aerospace structural components. This paper is devoted to proposing the interaction theory of the vibration and dynamic force, which is verified in the milling of Al 7075-T651 by consideration both the machine tool load and machining process dynamic load. First, through detailed analysis of the interaction effect of vibration and the dynamic force, the dynamic milling process is simplified to theoretically model the dynamic interaction in the precision manufacturing process under non-chatter condition. Then, the dynamic process force, which is the key source of the interaction, is modeled and obtained based on wavelet packet transform preprocess; the Frequency Response Function (FRF) of machine tool is regarded as the interaction link between the dynamic force load and the vibration response; the machine tool non-cutting vibration is transformed as a special dynamic load superposed on the response. Finally, the interaction vibration is calculated applying interaction effect model, the predicated results obtained in interaction effect approach match well with the vibration signal directly obtained in the test.

Digital twin of the technological process for grinding helical flutes of a cutting tool

“…The development of production systems, the creation of a digital environment to support the technological process [2][3][4][5][6][7] with access to CNC systems [8][9][10] and the monitoring of information about the cutting from sensors [11][12][13][14] has made it possible to increase the requirements for accuracy and improve the design complexity of tool designs [15][16][17][18][19][20]. In this connection, to ensure production flexibility, it is necessary to use such flexible methods of technological preparation as the possibilities for producing various standard sizes of end mill designs are wide.…”