Milling stability analysis using the spectral method

This paper focuses on the development of an efficient semi-analytical solution of chatter stability in milling based on the spectral method for integral equations. The time-periodic dynamics of the milling process taking the regenerative effect into account is formulated as a delayed differential equation with time-periodic coefficients, and then reformulated as a form of integral equation. On the basis of one tooth period being divided into a series of subintervals, the barycentric Lagrange interpolation polynomials are employed to approximate the state term and the delay term in the integral equation, respectively, while the Gaussian quadrature method is utilized to approximate the integral tenn. Thereafter, the Floquet transition matrix within the tooth period is constructed to predict the chatter stability according to Floquet theory. Experimental-validated one-degree-of-freedom and two-degree-of-freedom milling examples are used to verify the proposed algorithm, and compared with existing algorithms, it has the advantages of high rate of convergence and high computational efficiency.

ANALYSIS OF ROLL SYSTEM STABILITY ABOUT ALUMINUM FOIL MILLS

To improve roll system stability of aluminum foil mills, roll system stability of 2200 highspeed aluminum foil mill is analyzed with energy stable method. Two different restrictive conditions which gaps between chock of work roll and window of stand whether exist or not, are studied respectively. A new concept of roll system with open /closed compound pair conies up with as well for re-newably synthesizing restrictive mechanism of aluminum foil mills' chock. Through these studies, the conflict, whether reserving the gap for the roller replacement or eliminating the gap for roller's normal work, is successfully settled. This concept and analyzed result give the actual mechanism with open/closed compound restriction and the method of realizing high-speed rolling and prolonging longevity of end thrust bearing on work roll. It has important theoretical meaning and engineering value for modern technical reform of aluminum foil mills and plate strip mills.

A multi-order method for predicting stability of a multi-delay milling system considering helix angle and run-out effects

In this paper, a multi-delay milling system considering helix angle and run-out effects is firstly established. An exponential cutting force model is used to model the interaction between a work-piece and a cutting tool, and a new approach is presented for accurately calibrating exponential cutting force coefficients and cutter run-out parameters. Furthermore, based on an implicit multi-step Adams formula and an improved precise time-integration algorithm, a novel stability prediction method is proposed to predict the stability of the system. The involved time delay term and periodic coefficient term are integrated as a comprehensive state term in the integral response which is approximated by the Adams formula. Then, a Floquet transition matrix with an arbitraryorder form is constructed by using a series of matrix multiplication, and the stability of the system is determined by the Floquet theory. Compared to classical semi-discretization methods and fulldiscretization methods, the developed method shows a good performance in convergence, efficiency,accuracy, and multi-order complexity. A series of cutting tests is further carried out to validate the practicability and effectiveness of the proposed method. The results show that the calibration process needs a time of less than 5 min, and the stability prediction method is effective.

A Gaussian process regression‐based surrogate model of the varying workpiece dynamics for chatter prediction in milling of thin‐walled structures

Since the dynamics of thin‐walled structures instantaneously varies during the milling process,accurate and efficient prediction of the in‐process workpiece(IPW)dynamics is critical for the prediction of chatter stability of milling of thin‐walled structures.This article presents a surrogate model of the IPW dynamics of thin‐walled structures by combining Gaussian process regression(GPR)with proper orthogonal decomposition(POD)when IPW dynamics at a large number of cutting positions has to be predicted.The GPR method is used to learn the mapping between a set of the known IPW dynamics and the corresponding cutting positions.POD is used to reduce the order of the matrix assembled by the mode shape vectors at different cutting positions,before the GPR model of the IPW mode shape is established.The computation time of the proposed model is mainly composed of the time taken for predicting a known set of IPW dynamics and the time taken for training GPR models.Simulation shows that the proposed model requires less computation time.Moreover,the accuracy of the proposed model is comparable to that of the existing methods.Comparison between the predicted stability lobe diagram and the experimental results shows that IPW dynamics predicted by the proposed model is accurate enough for predicting the stability of milling of thin‐walled structures.

Preparation of stable colloidal suspensions of superdisintegrants via wet stirred media milling

Superdisintegrants are cross-linked polymers that can be used as dispersants for fast release of drug nanoparticles from nanocomposite microparticles during in vitro and in vivo dissolution. Currently avail- able superdisintegrant particles have average sizes of approximately 5-130 μm, which are too big for drug nanocomposite applications. Hence, production of stable superdisintegrant suspensions with less than 5 μm particles is desirable. Here, we explore the preparation of colloidal suspensions of anionic and nonionic superdisintegrants using a wet stirred media mill and assess their physical stability. Sodium starch glycolate （SSG） and crospovidone （CP） were selected as representative anionic and nonionic superdisintegrants, and hydroxypropyl cellulose （HPC） and sodium dodecyl sulfate （SDS） were used as a steric stabilizer and a wetting agent/stabilizer, respectively. Particle sizing, scanning electron microscopy, and zeta potential measurements were used to characterize the suspensions. Colloidal superdisintegrant suspensions were prepared reproducibly. The extensive particle breakage was attributed to the swelling-induced softening in water. SSG suspensions were stable even in the absence of stabilizers, whereas CP suspensions required HPC-SDS for minimizing particle aggregation. These findings were explained by the higher absolute （negative） zeta potential of the suspensions of the anionic superdisintegrant （SSG） as compared with those of the nonionic superdisintegrant （CP）.