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
The milling stability of thin-walled components is an important issue in the aviation manufacturing industry, which greatly limits the removal rate of a workpiece. However, for a thin-walled workpiece, the dynamic cha...The milling stability of thin-walled components is an important issue in the aviation manufacturing industry, which greatly limits the removal rate of a workpiece. However, for a thin-walled workpiece, the dynamic characteristics vary at different positions. In addition, the removed part also has influence on determining the modal parameters of the workpiece. Thus,the milling stability is also time-variant. In this work, in order to investigate the time variation of a workpiece＇s dynamic characteristics, a new computational model is firstly derived by dividing the workpiece into a removed part and a remaining part with the Ritz method. Then, an updated frequency response function is obtained by Lagrange＇s equation and the corresponding modal parameters are extracted. Finally, multi-mode stability lobes are plotted by the different quadrature method and its accuracy is verified by experiments. The proposed method improves the computational efficiency to predict the time-varying characteristics of a thin-walled workpiece.展开更多
Inspection techniques for aero-engine blades are a hot topic in industry. Since these blades have a sculptured surface and a small datum, measurement results may deviate from an actual position. There are few proper a...Inspection techniques for aero-engine blades are a hot topic in industry. Since these blades have a sculptured surface and a small datum, measurement results may deviate from an actual position. There are few proper approaches compensating for non-uniform distribution errors that are within specified tolerance ranges. This study aimed to develop a meshing structure measuring approach for the distortion of blades via non-contact optical 3D scanning. A rough measurement and a registration procedure are initially adopted to rectify the coordinate system of a blade, which avoids the initial coordinate system errors caused by the small datum. A measurement path with meshing structure is then unfolded on the blade surface. For non-uniform distribution errors, the meshing structure measurement is more visual and clear than the traditional constant height curves method. All measuring points take only 7 min to complete, and the distribution of error is directly and accurately presented by the meshing structure. This study provides a basis for future research on distortion control and error compensation.展开更多
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.
基金co-supported by the National Natural Science Foundation of China (No.51575319)the Young Scholars Program of Shandong University (No. 2015WLJH31)+1 种基金the Major National Science and Technology Project (No. 2014ZX04012-014)the Tai Shan Scholar Foundation (No. TS20130922)
文摘The milling stability of thin-walled components is an important issue in the aviation manufacturing industry, which greatly limits the removal rate of a workpiece. However, for a thin-walled workpiece, the dynamic characteristics vary at different positions. In addition, the removed part also has influence on determining the modal parameters of the workpiece. Thus,the milling stability is also time-variant. In this work, in order to investigate the time variation of a workpiece＇s dynamic characteristics, a new computational model is firstly derived by dividing the workpiece into a removed part and a remaining part with the Ritz method. Then, an updated frequency response function is obtained by Lagrange＇s equation and the corresponding modal parameters are extracted. Finally, multi-mode stability lobes are plotted by the different quadrature method and its accuracy is verified by experiments. The proposed method improves the computational efficiency to predict the time-varying characteristics of a thin-walled workpiece.
基金supported by a grant from the National Science and Technology Major Projects of China (No. 2013ZX04001051)
文摘Inspection techniques for aero-engine blades are a hot topic in industry. Since these blades have a sculptured surface and a small datum, measurement results may deviate from an actual position. There are few proper approaches compensating for non-uniform distribution errors that are within specified tolerance ranges. This study aimed to develop a meshing structure measuring approach for the distortion of blades via non-contact optical 3D scanning. A rough measurement and a registration procedure are initially adopted to rectify the coordinate system of a blade, which avoids the initial coordinate system errors caused by the small datum. A measurement path with meshing structure is then unfolded on the blade surface. For non-uniform distribution errors, the meshing structure measurement is more visual and clear than the traditional constant height curves method. All measuring points take only 7 min to complete, and the distribution of error is directly and accurately presented by the meshing structure. This study provides a basis for future research on distortion control and error compensation.
