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.

[1]  Gilles Dessein,et al.  INFLUENCE OF MATERIAL REMOVAL ON THE DYNAMIC BEHAVIOR OF THIN-WALLED STRUCTURES IN PERIPHERAL MILLING , 2004 .

[2]  Henk Nijmeijer,et al.  An improved tool path model including periodic delay for chatter prediction in milling , 2007 .

[3]  Yusuf Altintas,et al.  Multi frequency solution of chatter stability for low immersion milling , 2004 .

[4]  Qinghua Song,et al.  Prediction of simultaneous dynamic stability limit of time–variable parameters system in thin-walled workpiece high-speed milling processes , 2011 .

[5]  Yusuf Altintas,et al.  Analytical Prediction of Chatter Stability in Milling—Part II: Application of the General Formulation to Common Milling Systems , 1998 .

[6]  Gilles Dessein,et al.  Surface roughness variation of thin wall milling, related to modal interactions , 2008 .

[7]  Michele Monno,et al.  Efficient evaluation of process stability in milling with Spindle Speed Variation by using the Chebyshev Collocation Method , 2014 .

[8]  Francisco J. Campa,et al.  Stability limits of milling considering the flexibility of the workpiece and the machine , 2005 .

[9]  Gabor Stepan,et al.  Spectral element method for stability analysis of milling processes with discontinuous time-periodicity , 2017 .

[10]  Yusuf Altintas,et al.  Analytical Prediction of Stability Lobes in Milling , 1995 .

[11]  Yi Wan,et al.  Application of Sherman-Morrison-Woodbury formulas in instantaneous dynamic of peripheral milling for thin-walled component , 2015 .

[12]  S. A. Tobias.  Machine-tool vibration , 1965 .

[13]  Yusuf Altintas,et al.  Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design , 2000 .

[14]  Zhao Liang Jiang,et al.  Error compensation of thin plate-shape part with prebending method in face milling , 2015 .

[15]  Ming Luo,et al.  Material removal process optimization for milling of flexible workpiece considering machining stability , 2011 .

[16]  Gilles Dessein,et al.  Integration of dynamic behaviour variations in the stability lobes method: 3D lobes construction and application to thin-walled structure milling , 2006 .

[17]  Qinghua Song,et al.  Subdivision of chatter-free regions and optimal cutting parameters based on vibration frequencies for peripheral milling process , 2014 .

[18]  Mark Richardson,et al.  PARAMETER ESTIMATION FROM FREQUENCY RESPONSE MEASUREMENTS USING RATIONAL FRACTION POLYNOMIALS (TWENTY YEARS OF PROGRESS) , 1982 .

[19]  Yi Wan,et al.  Dynamic analysis of rectangular thin plates of arbitrary boundary conditions under moving loads , 2016 .

[20]  Han Ding,et al.  Stability Analysis of Milling Via the Differential Quadrature Method , 2013 .

[21]  Han Ding,et al.  A full-discretization method for prediction of milling stability , 2010 .

[22]  S. Smith,et al.  Update on high-speed milling dynamics. , 1990 .

[23]  Ye Ding,et al.  Stability analysis in milling of thin-walled workpieces with emphasis on the structural effect , 2010 .

[24]  Sinniah Ilanko,et al.  Proof of convergence for a set of admissible functions for the Rayleigh-Ritz analysis of beams and plates and shells of rectangular planform , 2015 .

[25]  S Herranz,et al.  The milling of airframe components with low rigidity: A general approach to avoid static and dynamic problems , 2005 .

[26]  Gnana K. Bharathy,et al.  Positive and negative penalty parameters in optimisation subjected to continuous constraints , 2012 .

[27]  B. Mann,et al.  Stability of Interrupted Cutting by Temporal Finite Element Analysis , 2003 .

[28]  Sinniah Ilanko,et al.  The Rayleigh-Ritz Method for Structural Analysis: Ilanko/The Rayleigh-Ritz Method for Structural Analysis , 2014 .