Vibration response analysis of thin-walled workpiece considering material removal effects during machining with variable pitch end mill

Zheng, M.Y.; Liu, Yuexiu; Nie, Wanying; Xu, Shicheng; Bi, Yuqi

doi:10.1007/s00170-022-10299-9

Cited by 6 publications

(2 citation statements)

References 28 publications

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“…Tehranizadeh et al conducted an analysis and comparison of the standard, variable-pitch and wave cutters for suppressing chatter in thin-walled milling, whose experiment results demonstrated that the wave cutter has a certain degree of advantage in chatter suppression for thin-walled machining and this cutter can effectively reduce chatter in thin-walled machining [26]. Zheng et al creates a cutting force model for variable-pitch end mills and confirms the link between material removal and vibration response using the optimal inter-tooth angle [27]. Guo et al devises a non-uniform helical tool dynamics equation and suggests cutting stability limitations.…”

Section: Introductionmentioning

confidence: 96%

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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Section: Introductionmentioning

confidence: 96%

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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show abstract

“…Jia et al 16 designed a pneumatic fixture to control support force on the thin-walled workpiece, and the three dimension stability lobe diagrams were obtained to predict the chatter stability. Zheng et al 17 obtained the relationship between material removal and vibration response and indicated the vibration amplitude of processing system increases as the workpiece thickness lessens. Sun et al 18 proposed a novel stability analysis method for rotary ultrasonic milling thin-walled workpiece through defining an ultrasonic function angle, and the stability lobe diagrams were achieved according to the semi-discrete method.…”

Section: Introductionmentioning

confidence: 99%

Study on chatter suppression in ultrasonic-assisted grinding of thin-walled workpiece of SiCp/Al composites

Dong

Bian

et al. 2023

Advances in Mechanical Engineering

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To suppress chatter is very important for ensuring processing quality and efficiency in ultrasonic-assisted grinding of thin-walled workpiece of SiCp/Al composites. Based on the chatter mechanism analysis, a stability analysis model is built and the analytical method is proposed. The cutting parameters can be selected reasonably based on the lobe diagram of stability, and the experiments were conducted using the parameters of selected points on lobe diagram. The experimental results show that the cutting force and surface roughness of unstable points are much larger than that of stable points, the vibration marks appear on the workpiece surface with unstable machining, and the surface quality is better in stable machining, which indicate that the chatter could be suppressed by this method to guarantee machining quality and efficiency.

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Research on surface integrity and its influencing factors in the high-speed cutting of typical aluminum/titanium/nickel alloys: a review

Wang

2023

Int J Adv Manuf Technol

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Vibration response analysis of thin-walled workpiece considering material removal effects during machining with variable pitch end mill

Cited by 6 publications

References 28 publications

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

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

Study on chatter suppression in ultrasonic-assisted grinding of thin-walled workpiece of SiCp/Al composites

Research on surface integrity and its influencing factors in the high-speed cutting of typical aluminum/titanium/nickel alloys: a review

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