薄壁件变参数铣削系统动态特性的研究

提出一种薄壁件变参数铣削系统动态特性分析方法。考虑铣削过程中的自激振动和强迫振动,建立了薄壁件变参数(模态质量、模态阻尼和模态刚度)铣削系统周期延迟微分方程,借助有限单元法和最小二乘法,获得加工过程中工件系统固有频率和模态质量随刀具位置的连续变化曲线。研究结果显示,薄壁件加工过程中,材料切除对系统动态特性有重要影响。实际加工时,应采取相应措施避免剧烈振动的发生。     

Error Compensation of Thin Plate-shape Part with Prebending Method in Face Milling

Low weight and good toughness thin plate parts are widely used in modern industry, but its flexibility seriously impacts the machinability. Plenty of studies focus on the influence of machine tool and cutting tool on the machining errors. However, few researches focus on compensating machining errors through the fixture. In order to improve the machining accuracy of thin plate-shape part in face milling, this paper presents a novel method for compensating the surface errors by prebending the workpiece during the milling process. First, a machining error prediction model using finite element method is formulated, which simplifies the contacts between the workpiece and fixture with spring constraints. Milling forces calculated by the micro-unit cutting force model are loaded on the error prediction model to predict the machining error. The error prediction results are substituted into the given formulas to obtain the prebending clamping forces and clamping positions. Consequently, the workpiece is prebent in terms of the calculated clamping forces and positions during the face milling operation to reduce the machining error. Finally, simulation and experimental tests are carried out to validate the correctness and efficiency of the proposed error compensation method. The experimental measured flatness results show that the flatness improves by approximately 30 percent through this error compensation method. The proposed method not only predicts the machining errors in face milling thin plate-shape parts but also reduces the machining errors by taking full advantage of the workpiece prebending caused by fixture, meanwhile, it provides a novel idea and theoretical basis for reducing milling errors and improving the milling accuracy.     

Partial Surface Damper to Suppress Vibration for Thin Walled Plate Milling

The material removal rate and required workpiece surface quality of thin-walled structure milling are greatly limited due to its severe vibration, which is directly associated with the dynamic characteristics of the system. Therefore, the suppression of vibration is an unavoidable problem during milling. A novel partial surface damping method is proposed to modify the mode of the thin walled cantilever plate and to suppress vibration during milling. Based on classical plate theory, the design criterion is analyzed and configuration of the partial surface damper is introduced, in which viscoelastic plate and constraining plate are attached to the surface of the plate to increase the system’s natural frequency and loss factor. In order to obtain the energy expression of the cutting system, the Ritz method is used to describe the unknown displacements. Then, with Lagrange’s equation, the natural frequency and loss factor are calculated. In addition, the plate is divided into a finite number of square elements, and the regulation of treated position is studied based on theoretic and experimental analysis. The milling tests are conducted to verify its damping performance and the experimental results show that with treatment of partial surface damper, the deformation of the bare plate is reduced from 0.27 mm to 0.1 mm, while the vibration amplitude of the bare plate is reduced from 0.08 mm to 0.01 mm. The proposed research provides the instruction to design partial surface damper.     

SIMULATION CONCEPT FOR PREDICTING WORKPIECE VIBRATIONS IN FIVE-AXIS MILLING

The characteristic discontinuous cut of the milling process influences the whole machining process by an increased susceptibility to vibrations of the machine-tool-workpiece system. This can result in undesirable effects on the workpiece surface or in a shorter lifetime of the tool and the spindle. Especially with regard to the machining of thin-walled components, such as turbine blades and thin profiles, the dynamic behavior of the workpiece is of particular interest. In this paper a simulation concept for predicting regenerative workpiece vibrations during the five-axis milling process is presented. This concept combines an accurate and fast simulation of the five-axis machining process including material removal and force calculation with an implemented finite element model for computing workpiece displacements. The simulation results are compared with data from experiments, which were conducted using a milling tool with high stiffness in order to minimize the influence of the milling tool dynamics.     

Milling Force Model for Aviation Aluminum Alloy:Academic Insight and Perspective Analysis

Aluminum alloy is the main structural material of aircraft,launch vehicle,spaceship,and space station and is pro-cessed by milling.However,tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy.The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters,material mechanical properties,machine tools,and other parameters.In particular,milling force is the crucial factor to determine material removal and workpiece surface integrity.However,establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system.The research progress of cutting force model is reviewed from three modeling methods:empirical model,finite element simulation,and instantaneous milling force model.The problems of cutting force modeling are also determined.In view of these problems,the future work direction is proposed in the following four aspects:(1)high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth,which easily produces high residual stress.The residual stress should be analyzed under this particular condition.(2)Multiple factors(e.g.,eccentric swing milling parameters,lubrication conditions,tools,tool and workpiece deformation,and size effect)should be consid-ered comprehensively when modeling instantaneous milling forces,especially for micro milling and complex surface machining.(3)The database of milling force model,including the corresponding workpiece materials,working condi-tion,cutting tools(geometric figures and coatings),and other parameters,should be established.(4)The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling.(5)The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication(mql)and nanofluid mql should be predicted.     

INFLUENCE OF MATERIAL REMOVAL ON THE DYNAMIC BEHAVIOR OF THIN-WALLED STRUCTURES IN PERIPHERAL MILLING

Machining is a material removal process that alters the dynamic properties during machining operations. The peripheral milling of a thin-walled structure generates vibration of the workpiece and this influences the quality of the machined surface. A reduction of tool life and spindle life can also be experienced when machining is subjected to vibration. In this paper, the linearized stability lobes theory allows us to determine critical and optimal cutting conditions for which vibration is not apparent in the milling of thin-walled workpieces. The evolution of the mechanical parameters of the cutting tool, machine tool and workpiece during the milling operation are not taken into account. The critical and optimal cutting conditions depend on dynamic properties of the workpiece. It is illustrated how the stability lobes theory is used to evaluate the variation of the dynamic properties of the thin-walled workpiece. We use both modal measurement and finite element method to establish a 3D representation of stability lobes. The 3D representation allows us to identify spindle speed values at which the variation of spindle speed is initiated to improve the surface finish of the workpiece.     

INFLUENCE OF MATERIAL REMOVAL ON THE DYNAMIC BEHAVIOR OF THIN-WALLED STRUCTURES IN PERIPHERAL MILLING

Machining is a material removal process that alters the dynamic properties during machining operations. The peripheral milling of a thin-walled structure generates vibration of the workpiece and this influences the quality of the machined surface. A reduction of tool life and spindle life can also be experienced when machining is subjected to vibration. In this paper, the linearized stability lobes theory allows us to determine critical and optimal cutting conditions for which vibration is not apparent in the milling of thin-walled workpieces. The evolution of the mechanical parameters of the cutting tool, machine tool and workpiece during the milling operation are not taken into account. The critical and optimal cutting conditions depend on dynamic properties of the workpiece. It is illustrated how the stability lobes theory is used to evaluate the variation of the dynamic properties of the thin-walled workpiece. We use both modal measurement and finite element method to establish a 3D representation of stability lobes. The 3D representation allows us to identify spindle speed values at which the variation of spindle speed is initiated to improve the surface finish of the workpiece.     

Time domain coupled simulation of machine tool dynamics and cutting forces considering the influences of nonlinear friction characteristics and process damping

A higher machining ability is always required for NC machine tools to achieve higher productivity. The self-oscillated vibration called “chatter” is a well-known and significant problem that increases the metal removal rate. The generation process of the chatter vibration can be described as a relationship between cutting force and machine tool dynamics. The characteristics of machine tool feed drives are influenced by the nonlinear friction characteristics of the linear guides. Hence, the nonlinear friction characteristics are expected to affect the machining ability of machines. The influence of the contact between the cutting edge and the workpiece (i.e., process damping) on to the machining ability has also been investigated. This study tries to clarify the influence of the nonlinear friction characteristics of linear guides and ball screws and process damping onto milling operations. A vertical-type machining center is modeled by a multi-body dynamics model with nonlinear friction models. The influence of process damping onto the machine tool dynamics is modeled as stiffness and damping between the tool and the workpiece based on the evaluated frequency response during the milling operation. A time domain-coupled simulation approach between the machine tool behavior and the cutting forces is performed by using the machine tool dynamics model. The simulation results confirm that the nonlinear frictions influence the cutting forces with an effect to suppress the chatter vibration. Furthermore, the influence of process damping can be evaluated by the proposed measurement method and estimated by a time domain simulation.     

Prediction of simultaneous dynamic stability limit of time�Cvariable parameters system in thin-walled workpiece high-speed milling processes

A method for predicting simultaneous dynamic stability limit of thin-walled workpiece high-speed milling process is described. The proposed approach takes into account the variations of dynamic characteristics of workpiece with the tool position. A dedicated thin-walled workpiece representative of a typical industrial application is designed and modeled by finite element method. The curvilinear equation of modal characteristics changing with tool position is regressed. A specific dynamic stability lobe diagram is then elaborated by scanning the dynamic properties of workpiece along the machined direction throughout the machining process. The results show that, during thin-walled workpiece milling process, material removing plays an important part on the change of dynamic characteristics of system, and the stability limit curves are dynamic curves with time?Cvariable. In practical machining, some suggestion is interpreted in order to avoid the vibrations and increase the chatter free material removal rate and surface finish. Then investigations are compared and verified by high-speed milling experiments with thin-walled workpiece.     

Dynamics model of active fixturing systems for thin-walled parts under moving loads

This work presents a modelling approach that captures the dynamic response of active fixture elements and thin-walled workpieces subjected to dynamic moving loads. The impedance coupling method is deployed to achieve the integration of analytical expressions for the active elements and a discretised finite element-based model of a workpiece. The proposed model is validated experimentally and analytically via a test case, involving a single active fixture element in contact with a thin aluminium plate subjected to an evenly distributed dynamic moving load. A very good agreement is observed between the time response of the modelled and the experimental system to step and harmonic inputs. The moving load modelling approach presents a maximum error of ε?=?5.82% in terms of predicting the dynamic elastic deformation of the workpiece in comparison to an analytical model.     

Three-dimensional process stability prediction of thin-walled workpiece in milling operation

High-speed machining of thin-walled workpiece is widely used in aerospace industry. To optimize the machining parameters in milling operations, the related process stability is required to be predicted. Compared to the existing two-dimensional (2D) milling stability model, a more completed three-dimensional (3D) regenerative process stability prediction model of thin-walled workpiece is presented based on the newly developed dynamic model. The efficiency and accuracy of the regenerative milling stability can be improved in the presented 3D model. The analysis procedure of the stability of flexible dynamic milling is developed in details. The 3D stability lobes are calculated according to the full discretization method and direct integration scheme. To verify the accuracy of presented 3D stability model, the thin-walled workpiece milling sound pressure signal and surface quality are determined in experiments.     

基于有限元数值模型和进给速度优化的薄壁件侧铣变形在线控制

为实现在加工过程中对薄壁件侧铣产生的较大切削变形进行在线控制,提出基于有限元数值模型和进给速度优化的在线控制策略。根据薄壁件切削过程的有限元仿真结果,建立数控机床进给速度、切削力、工件切削变形间的数值模型,进而确定用于控制变形的最优目标切削力。在具有开放式模块化的数控系统平台上开发了切削力信号实时采集、滤波功能和基于Brent-Dekker算法的进给速度在线优化策略,并根据滤波后的切削力及相应算法在加工过程中实时调整机床进给速度,保证切削力逐渐接近最优控制目标而实现切削变形的在线控制。试验结果表明,经过进给速度在线优化后的切削过程可将薄壁件侧铣变形控制在规定范围内,同时提高了切削效率。     

An Integrated Model of a Fixture-Workpiece System for Surface Quality Prediction

Surface quality is a major factor affecting the performance of a component. The machined surface quality is strongly influenced by the external loads during the fixturing and machining processes. In machining process development, it is highly desirable to predict the quality of a machined surface. For this purpose, an integrated finite element analysis (FEA) model of the entire fixture–workpiece system is developed to investigate the influence of clamping preload and machining force on the surface quality of the machined workpiece. The effects of fixture and machine table compliance (from experimental data), and the workpiece and its locators/clamps contact interaction, and forced vibration, on the machined surface quality are taken into account. This simulation model provides a better understanding of the causes of surface error and a more realistic prediction of the machined surface quality. The deck face of a V-type engine block subjected to fixture clamping and a face milling operation is given as an example. A comparison between the simulation result and experimental data shows a reasonable agreement.     

A time-space discretization method in milling stability prediction of thin-walled component

The stability prediction of thin-walled workpiece milling is an awkward problem due to the time variant of dynamic characteristics during milling process. Integrating the time discretization method for stability prediction mentioned in many articles, a novel time-space discretization method for thin-walled component milling stability prediction is proposed based on thin plate theory and mode superposition principle, which includes the effects of the engagement position between cutter and workpiece and multi-modes of the system. The results show that the method presented is very reliable and efficient, and its accuracy is also in good agreement with experimental results. Additionally, the method can be used to handle various complex boundary conditions by means of the updated Rayleigh-Ritz solutions together with the penalty method. Two case studies are performed to explain the validation of the method as well as milling experiments of a half-clamped thin plate.     

薄壁零件高速铣削稳定性预测与验证

针对薄壁零件高速铣削加工系统小刚度、动态变化的频响特点和高阶动态特性,研究其无颤振稳定铣削的极限预测理论。针对薄壁结构小刚度的频响特性,建立由刀具子系统和工件子系统之间的相对动态特性决定的铣削动力学模型和无颤振稳定切削的临界条件;针对高速铣削的高转速特点,建立基于多自由度系统高阶动态特性的稳定性极限预测模型;针对薄壁结构在加工过程中其动态特性的时变性,提出通过跟踪工件在不同加工阶段的动态特性进行稳定性极限预测的方法。对典型薄壁结构进行切削试验,试验结果验证了所提出的稳定性预测模型和预测方法的有效性。     

虚拟加工过程薄壁工件铣削变形模型研究

在薄壁工件的切削加工中,工件的受力变形是影响加工过程的一个主要因素,文中针对薄壁工件侧面的立铣加工,建立了不同复杂度的切削过程模型,以仿真工件薄壁在加工中受到切削力发生的变形,虚拟实现受到工件变形影响下的切削过程。通过仿真创成的工件表面形貌与实际切成的工件表面的比较,对文中各模型进行了验证。     

Chatter prediction utilizing stability lobes with process damping in finish milling of titanium alloy thin-walled workpiece

Machining chatter often becomes a big hindrance to high productivity and surface quality in actual milling process, especially for the thin-walled workpiece made of titanium alloy due to poor structural stiffness. Aiming at this issue, the stability lobes are usually employed to predict if chatter may occur in advance. For obtaining the stability lobes in milling to avoid chatter, this article introduces an extended dynamic model of milling system considering regeneration, helix angle, and process damping into the high-order time domain algorithm which can guarantee both high computational efficiency and accuracy. Via stability lobes, the reasonability and accuracy of the proposed method are verified globally utilizing specific examples in literature. More convincingly, the time-domain numerical simulation is also implemented to predict vibration displacement for partial stability verification. In this extended model, process damping is well-known as an effective approach to improve the stability at low spindle speeds, and particularly, titanium alloy as typical difficult-to-machine material is generally machined at low spindle speeds as well due to its poor machinability. Therefore, the proposed method can be employed to obtain the 3D stability lobes in finish milling of the thin-walled workpiece made of titanium alloy, Ti-6Al-4V. Verification experiments are also conducted and the results show a close agreement between the stability lobes and experiments.     

薄壁件铣削过程仿真与分析

针对薄壁件加工过程中易产生变形等问题，提出了利用有限元法对铣削过程进行三维仿真的方法，重点研究了LS-DYNA的动态接触算法，建立了薄壁件铣削加工的有限元模型，对工件变形及切削力的变化规律进行了分析。最后，利用分析结果对铣削参数进行调整与优化，可以减小工件变形，保证加工精度。     

薄壁筒件内孔车削振动建模与分析

分析了车削薄壁筒件内孔表面时影响振动的主要因素,以切削加工中工件过渡表面的法线方向为建模方向,重点考虑车削加工中动态切削力的影响,依据振动基本理论建立了薄壁筒件动态车削过程的振动模型方程,通过对方程的数值分析探讨加工过程中的振动问题。分析结果表明:切削用量三要素对动态切削力的影响起主导作用,进而对切削振动产生较大影响。刀具主偏角对动态切削力也有一定影响,车削产生的振动与主偏角之间是非线性的关系。这些结论为薄壁筒件加工中的振动研究提供有益的参考。     

实时振动数据驱动的薄壁件平铣工艺参数自适应优化

为减小加工振动对薄壁件平铣（端面盘铣）加工质量及效率的影响,提出一种实时铣削振动数据驱动的平铣工艺参数自适应优化方法。首先根据再生效应原理建立薄壁件平铣颤振稳定性模型。其次将薄壁件平铣过程中前一个工步内的实测振动数据分为若干段,以此模拟其材料去除过程,对各段铣削振动数据进行分析,由有限元单位力法和优化STD法分别识别出薄壁件刚度和各材料去除阶段模态频率及阻尼比,并由此导出薄壁件单模态频响函数,将其代入颤振稳定性模型求解稳定域叶瓣图并做插值处理后即可确定包含材料去除信息的薄壁件三维颤振稳定域叶瓣图。基于此,以避免铣削颤振、共振和满足机床性能要求为约束条件,以材料去除率最大为目标,利用遗传算法计算薄壁件下一个工步较优的工艺参数,如此循环进行,直到完成薄壁件加工。最后,通过某型飞机垂尾薄壁装配界面平铣试验验证该方法的可行性和有效性。由试验结果可看出,采用优化后的加工工艺参数,能使薄壁装配界面粗加工过程表面粗糙度从Ra 3.2提升为Ra 1.6,加工效率提高33%。