Journal ArticleDOI
Predictive modeling of chatter stability considering force-induced deformation effect in milling thin-walled parts
Yuwen Sun,Shanglei Jiang +1 more
TLDR
In this article, an accurate modeling of dynamic milling system with the force-induced deformation effect is presented, where both the thin-walled part and the cutter are discretized into differential elements, such that the influences of the force induced deformation and multi-point contact structure dynamics can be simultaneously considered at the contact zones.Abstract:
Force-induced deformation is an inevitable phenomenon in thin-wall milling operations, which makes the actual radial depth of cut deviate from its nominal value and changes tool-part engagement angle boundaries. This paper presents an accurate modeling of dynamic milling system with the force-induced deformation effect. Both the thin-walled part and the cutter are discretized into differential elements, such that the influences of the force-induced deformation and multi-point contact structure dynamics can be simultaneously considered at the contact zones. A detail flexible iteration strategy is first presented to calculate the force-induced deformation and the resulting tool-part engagement angle boundaries. After that, time-varying multi-modal dynamic parameters with actual material removal effect are obtained by simultaneously modifying structural static and dynamic stiffness at each tool feed position. The system involving regenerative dynamic displacements is formulated as a matrix of time-periodic delay differential equation. Chatter stability of the system is predicted by an extended second order semi-discretization method. Milling experiments are conducted to validate the proposed approach, and two types of parts with different wall thickness are designed. The results show that chatter can be well predicted by using the proposed approach.read more
Citations
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Journal ArticleDOI
Recent progress of chatter prediction, detection and suppression in milling
Lida Zhu,Changfu Liu +1 more
TL;DR: A critical review of chatter is presented, focusing on regenerative chatter and mode coupling chatter, and four directions for future research are presented, including integrating the chatter prediction, detection and suppression units into a smart machine tool or smart spindle.
Journal ArticleDOI
An efficient decomposition-condensation method for chatter prediction in milling large-scale thin-walled structures
TL;DR: In this paper, an efficient decomposition-condensation method is developed to predict the in-process workpiece dynamics for chatter prediction in finishing and semi-finishing large-scale thin-walled structures.
Journal ArticleDOI
Self-optimizing machining systems
TL;DR: Enabling technologies, principles, and methods are described that allow for the implementation of machining systems which are capable of adapting their parameters and settings autonomously, in order to optimize for productivity, quality, and efficiency in manufacturing.
Journal ArticleDOI
An accelerated convergence approach for real-time deformation compensation in large thin-walled parts machining
TL;DR: An approach based on the secant method, which provides a higher order of convergence, is developed and introduced into the real-time compensation process for large thin-walled plate machining.
Journal ArticleDOI
Adaptive machining for curved contour on deformed large skin based on on-machine measurement and isometric mapping
TL;DR: In this paper, a novel isometric mapping based adaptive machining method is developed to improve the contour cutting accuracy on large thin-walled skin by using a laser scanner based on-machine measurement (OMM) system.
References
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Book
Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design
TL;DR: In this paper, the authors discuss the application of metal cutting to manufacturing problems, including the design of real-time trajectory generation and interpolation algorithms, and CNC-oriented error analysis.
Journal ArticleDOI
Analytical Prediction of Stability Lobes in Milling
Yusuf Altintas,Erhan Budak +1 more
TL;DR: In this article, a new method for the analytical prediction of stability lobes in milling is presented, which requires transfer functions of the structure at the cutter -workpiece contact zone, static cutting force coefficients, radial immersion and the number of teeth on the cutter.
Journal ArticleDOI
Prediction of Milling Force Coefficients From Orthogonal Cutting Data
TL;DR: In this paper, the authors compared the mechanistic and unified mechanics of cutting approaches to the prediction of forces in milling operations and showed that the milling force coefficients for all force components and cutter geometrical designs can be predicted from an orthogonal cutting data base and the generic oblique cutting analysis for use in the predictive mechanistic milling models.
Journal ArticleDOI
Analytical Prediction of Chatter Stability in Milling-part I : General Formulation
Erhan Budak,Yusuf Altintas +1 more
TL;DR: In this paper, a general formulation for the dynamic milling system is developed by modeling the cutter and workpiece as multi-degree-of-freedom structures, considering the varying dynamics in the axial direction.
Journal ArticleDOI
Updated semi‐discretization method for periodic delay‐differential equations with discrete delay
Tamás Insperger,Gabor Stepan +1 more
TL;DR: In this paper, an updated version of the semi-discretization method is presented for periodic systems with a single discrete time delay, where the delayed term is approximated as a weighted sum of two neighboring discrete delayed state values and the transition matrix over a single period is determined.
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Updated semi‐discretization method for periodic delay‐differential equations with discrete delay
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