Considering the deficiency in milling process parameters selection, based on the modelling of dynamic milling force and the deduction of chatter stability limits, the chatter stability lobes simulation program for mil...Considering the deficiency in milling process parameters selection, based on the modelling of dynamic milling force and the deduction of chatter stability limits, the chatter stability lobes simulation program for milling is developed with MAT- LAB. The simulation optimization application software of dynamics was designed using engineering simulation software Visio Basic. The chatter stability lobes for milling, which can be used as an instruction guide for the selection of process parameters, are simulated with frequency response functions （FRFs） gained by hammer test. The validation and accuracy of the simulation algorithm are verified by experiments. The simulation method has been used in a factory with an excellent application effect.展开更多
Micro-milling technology is widely applied in micro manufacturing,particularly for the fabrication of miniature and micro components.However,the chatters and machining dynamics related issues in micro-milling are ofte...Micro-milling technology is widely applied in micro manufacturing,particularly for the fabrication of miniature and micro components.However,the chatters and machining dynamics related issues in micro-milling are often the main challenges restricting its machining quality and productivity.Many research works have rendered that the machining dynamics and chatters in micro-milling are more complex compared with the conventional macro-milling process,likely because of the size effect and rigidity of the micro-milling system including the tooling,workpiece,process variables,materials involved,and the high-speed milling machines,and further their collective dynamic effects.Therefore,in this paper,the state of the art focusing on micro-milling chatters and dynamics related issues over the past years are comprehensively and critically reviewed to provide some insights for potential researchers and practitioners.Firstly,typical applications and the problems caused by the machining dynamics and chatters in micro-milling have been put forward in this paper.Then,the research on the underlying micro-cutting mechanics and dynamics,stability analysis,chatters detection,and chatter suppression are summarized critically.Furthermore,the underlying scientific and technological challenges are discussed particularly against typical precision engineering applications.Finally,the possible future directions and trends in research and development of micro-milling have been discussed.展开更多
Milling of the thin-walled workpiece in the aerospace industry is a critical process due to the high flexibility of the workpiece. In this paper, a flexible fixture based on the magnetorheological (MR) fluids is desig...Milling of the thin-walled workpiece in the aerospace industry is a critical process due to the high flexibility of the workpiece. In this paper, a flexible fixture based on the magnetorheological (MR) fluids is designed to investigate the regenerative chatter suppression during the machining. Based on the analysis of typical structural components in the aerospace industry, a general complex thin-walled workpiece with fixture and damping constraint can be equivalent as a rectangular cantilever beam. On the basis of the equivalent models, natural frequency and mode shape function of the thin-walled workpiece is obtained according to the Euler-Bernoulli beam assumptions. Then, the displacement response function of the bending vibration of the beam is represented by the product of all the mode shape function and the generalized coordinate. Furthermore, a dynamic equation of the workpiece-fixture system considering the external damping factor is proposed using the Lagrangian method in terms of all the mode shape function and the generalized coordinate, and the response of system under the dynamic cutting force is calculated to evaluate the stability of the milling process under damping control. Finally, the feasibility and effectiveness of the proposed approach are validated by the impact hammer experiments and several machining tests. (C) 2016 Production and hosting by Elsevier Ltd. on behalf of Chinese Society of Aeronautics and Astronautics.展开更多
基金Tianjin Municipal Association of Higher Vocational&Technical Education Projects(No.XIV412)
文摘Considering the deficiency in milling process parameters selection, based on the modelling of dynamic milling force and the deduction of chatter stability limits, the chatter stability lobes simulation program for milling is developed with MAT- LAB. The simulation optimization application software of dynamics was designed using engineering simulation software Visio Basic. The chatter stability lobes for milling, which can be used as an instruction guide for the selection of process parameters, are simulated with frequency response functions （FRFs） gained by hammer test. The validation and accuracy of the simulation algorithm are verified by experiments. The simulation method has been used in a factory with an excellent application effect.
基金supported by the National Natural Science Foundation of China(No.52075129).
文摘Micro-milling technology is widely applied in micro manufacturing,particularly for the fabrication of miniature and micro components.However,the chatters and machining dynamics related issues in micro-milling are often the main challenges restricting its machining quality and productivity.Many research works have rendered that the machining dynamics and chatters in micro-milling are more complex compared with the conventional macro-milling process,likely because of the size effect and rigidity of the micro-milling system including the tooling,workpiece,process variables,materials involved,and the high-speed milling machines,and further their collective dynamic effects.Therefore,in this paper,the state of the art focusing on micro-milling chatters and dynamics related issues over the past years are comprehensively and critically reviewed to provide some insights for potential researchers and practitioners.Firstly,typical applications and the problems caused by the machining dynamics and chatters in micro-milling have been put forward in this paper.Then,the research on the underlying micro-cutting mechanics and dynamics,stability analysis,chatters detection,and chatter suppression are summarized critically.Furthermore,the underlying scientific and technological challenges are discussed particularly against typical precision engineering applications.Finally,the possible future directions and trends in research and development of micro-milling have been discussed.
基金supported by the National Basic Research Program of China (Grant No. 2013CB035802)the 111 Project of China (Grant No. B13044)
文摘Milling of the thin-walled workpiece in the aerospace industry is a critical process due to the high flexibility of the workpiece. In this paper, a flexible fixture based on the magnetorheological (MR) fluids is designed to investigate the regenerative chatter suppression during the machining. Based on the analysis of typical structural components in the aerospace industry, a general complex thin-walled workpiece with fixture and damping constraint can be equivalent as a rectangular cantilever beam. On the basis of the equivalent models, natural frequency and mode shape function of the thin-walled workpiece is obtained according to the Euler-Bernoulli beam assumptions. Then, the displacement response function of the bending vibration of the beam is represented by the product of all the mode shape function and the generalized coordinate. Furthermore, a dynamic equation of the workpiece-fixture system considering the external damping factor is proposed using the Lagrangian method in terms of all the mode shape function and the generalized coordinate, and the response of system under the dynamic cutting force is calculated to evaluate the stability of the milling process under damping control. Finally, the feasibility and effectiveness of the proposed approach are validated by the impact hammer experiments and several machining tests. (C) 2016 Production and hosting by Elsevier Ltd. on behalf of Chinese Society of Aeronautics and Astronautics.
