T-slot milling is one of the most common milling processes in industry. Despite recent advances in machining technology, productivity of T-slot milling is usually limited due to the process limitations such as high cu...T-slot milling is one of the most common milling processes in industry. Despite recent advances in machining technology, productivity of T-slot milling is usually limited due to the process limitations such as high cutting forces and stability. If cutting conditions are not selected properly the process may result in the poor surface finish of the workpiece and the potential damage to the machine tool. Currently, the predication of chatter stability and determination of optimal cutting conditions based on the modeling of T-slot milling process is an effective way to improve the material removal rate（MRR） of a T-slot milling operation. Based on the geometrical model of the T-slot cutter, the dynamic cutting force model was presented in which the average directional cutting force coefficients were obtained by means of numerical approach, and leads to an analytical determination of stability lobes diagram（SLD） on the axial depth of cut. A new kind of SLD on the radial depth of cut was also created to satisfy the special requirement of T-slot milling. Thereafter, a dynamic simulation model of T-slot milling was implemented using Matlab software. In order to verify the effectiveness of the approach, the transfer functions of a typical cutting system in a vertical CNC machining center were measured in both feed and normal directions by an instrumented hammer and accelerators. Dynamic simulations were conducted to obtain the predicated SLD under specified cutting conditions with both the proposed model and CutPro~. Meanwhile, a set of cutting trials were conducted to reveal whether the cutting process under specified cutting conditions is stable or not. Both the simulation comparison and experimental verification demonstrated that the satisfactory coincidence between the simulated, the predicted and the experimental results. The chatter-free T-slot milling with higher MRR can be achieved under the cutting conditions determined according to the SLD simulation.展开更多
在机床各种形式的振动中,再生颤振具有最小的稳定极限切削宽度,换言之,机床抵抗再生颤振的能力最差。品质系数(Coefficient of Merit,COM)是切削力和切削表面法向相对位移之间的交叉频响函数最小负实部的函数,其大小直接反映机床抵抗再...在机床各种形式的振动中,再生颤振具有最小的稳定极限切削宽度,换言之,机床抵抗再生颤振的能力最差。品质系数(Coefficient of Merit,COM)是切削力和切削表面法向相对位移之间的交叉频响函数最小负实部的函数,其大小直接反映机床抵抗再生颤振的能力。此外,在机床的连续使用过程中,品质系数COM会逐渐减小,进而影响机床再生颤振抗振能力。基于相对激振方法和四自由度立铣加工过程动力学模型,重点分析了机床相对动柔度劣化过程中品质系数COM的变化趋势,以及对加工过程稳定性Lobe图的影响。研究表明:随着机床相对动柔度的劣化,轴向极限切深ap逐渐减小,并有加速递减的趋势,这和机床品质系数的劣化趋势一致。因此,考虑机床相对动柔度对稳定性Lobe图的影响,才能确定更合适的工艺参数,保证切削过程的稳定性,提高加工效率。展开更多
基金supported by National Science and Technology Support Program of China (Grant No. 2006BAF01B09-03)the Research Fund for the Doctoral Program of Higher Education of China (Grant No. 200800060010)Hunan Provincial Educational Department Scientific Research Project of China (Grant No. 08D096)
文摘T-slot milling is one of the most common milling processes in industry. Despite recent advances in machining technology, productivity of T-slot milling is usually limited due to the process limitations such as high cutting forces and stability. If cutting conditions are not selected properly the process may result in the poor surface finish of the workpiece and the potential damage to the machine tool. Currently, the predication of chatter stability and determination of optimal cutting conditions based on the modeling of T-slot milling process is an effective way to improve the material removal rate（MRR） of a T-slot milling operation. Based on the geometrical model of the T-slot cutter, the dynamic cutting force model was presented in which the average directional cutting force coefficients were obtained by means of numerical approach, and leads to an analytical determination of stability lobes diagram（SLD） on the axial depth of cut. A new kind of SLD on the radial depth of cut was also created to satisfy the special requirement of T-slot milling. Thereafter, a dynamic simulation model of T-slot milling was implemented using Matlab software. In order to verify the effectiveness of the approach, the transfer functions of a typical cutting system in a vertical CNC machining center were measured in both feed and normal directions by an instrumented hammer and accelerators. Dynamic simulations were conducted to obtain the predicated SLD under specified cutting conditions with both the proposed model and CutPro~. Meanwhile, a set of cutting trials were conducted to reveal whether the cutting process under specified cutting conditions is stable or not. Both the simulation comparison and experimental verification demonstrated that the satisfactory coincidence between the simulated, the predicted and the experimental results. The chatter-free T-slot milling with higher MRR can be achieved under the cutting conditions determined according to the SLD simulation.
文摘在机床各种形式的振动中,再生颤振具有最小的稳定极限切削宽度,换言之,机床抵抗再生颤振的能力最差。品质系数(Coefficient of Merit,COM)是切削力和切削表面法向相对位移之间的交叉频响函数最小负实部的函数,其大小直接反映机床抵抗再生颤振的能力。此外,在机床的连续使用过程中,品质系数COM会逐渐减小,进而影响机床再生颤振抗振能力。基于相对激振方法和四自由度立铣加工过程动力学模型,重点分析了机床相对动柔度劣化过程中品质系数COM的变化趋势,以及对加工过程稳定性Lobe图的影响。研究表明:随着机床相对动柔度的劣化,轴向极限切深ap逐渐减小,并有加速递减的趋势,这和机床品质系数的劣化趋势一致。因此,考虑机床相对动柔度对稳定性Lobe图的影响,才能确定更合适的工艺参数,保证切削过程的稳定性,提高加工效率。
