scholarly journals Measurement-Based Modal Analysis and Stability Prediction on Turn-Milling of Hollow Turbine Blade

2020 ◽  
Vol 2020 ◽  
pp. 1-9
Author(s):  
Zhengcai Zhao ◽  
Junming Hou ◽  
Yucan Fu
Keyword(s):  
Modal Analysis ◽  
Damping Ratio ◽  
Stability Prediction ◽  
Stability Lobe Diagram ◽  
Structural Part ◽  
Stability Lobe ◽  
Hollow Blade ◽  
Machining System ◽  
The Impact ◽  
Turn Milling

Hollow blades with honeycomb structures are increasingly used in the turbine engines for reducing weight and saving costs. The hollow blade is a typical thin-walled structural part with low stiffness, the machining system of which is often unstable and likely to chatter. The most effective solution to avoid the machining chatter is to guide the hollow blade to be machined in a stable machining zone. This paper proposes a measurement-based approach for modal analysis and stability prediction of turn-milling hollow blade. The impact test was carried out to achieve the FRF curves on the hollow blade and the milling tool. An extremum method was employed to obtain an equivalent FRF curve, from which the modal parameters involving the natural frequency, damping ratio, and stiffness were computed. Afterwards, the semidiscretization method was used to draw a stability lobe diagram to predict the stability when turn-milling hollow blades. The experimental results confirm the feasibility of the predicted stability lobe diagram.

scholarly journals Identification of process damping for chatter prediction in milling

2018 ◽  
Vol 175 ◽  
pp. 02002
Author(s):  
Charles M. Zheng ◽  
Chou-Fu Liang ◽  
Hai-Yi Cai ◽  
Shui-Shen Zhang
Keyword(s):  
Damping Ratio ◽  
Depth Of Cut ◽  
Structural Damping ◽  
Stability Lobe Diagram ◽  
Easy Method ◽  
Process Damping ◽  
Stability Lobe ◽  
Mathematical Expressions ◽  
The Stability ◽  
The Impact

Traditionally, forecasting stability lobe diagram in milling is limited by complex damping identification procedures, so only structural damping from the impact experiment is used for predicting stability lobe diagram in most milling cases. In this study, by using the mathematical expressions among damping ratio, “critical limiting depth of cut” and “worst spindle speed”, it is shown that the predicted “critical limiting depth of cut” based on the structural damping divided by the measured “critical limiting depth of cut” can be approximately equal to the structural damping divided by the total damping. Based on this relationship, it is easy to estimate the total damping or process damping from the experiment within the selected spindle speeds. In practice, this paper presents an easy method for predicting stability lobe diagram using the total damping. At the same time, experiments have confirmed that using the prediction model of total damping can more accurately predict the stability lobe diagram.

Stability Prediction of Milling Process With Closed Machining System Dynamics With Flexible Thin-Walled Workpiece

2015 ◽  
Author(s):  
Chao Xu ◽  
Pingfa Feng ◽  
Dingwen Yu ◽  
Zhijun Wu ◽  
Jianfu Zhang
Keyword(s):  
Support System ◽  
Milling Process ◽  
Machining Process ◽  
Stability Lobe Diagram ◽  
Closed Model ◽  
Flexible Support ◽  
Stability Lobe ◽  
Machining System ◽  
Thin Walled ◽  
The Stability

Despite recent advances and improvements in modeling and prediction of the dynamics of the machining process, an efficient machining process is limited due to chatter and instability of machining system. In fact, the machining system contains various kinds of joints, which cause difficulties in dynamics modeling, simulation and prediction. Moreover, the flexible support system results in large deformation and violent vibration of the workpiece when machining, and the thin-walled workpiece easily gives rise to the chatter of the machining system. Therefore, the dynamics of the flexible support system was considered to calculate stability lobe diagram in the modeling of milling process. The whole machining system was regarded as a closed loop composed by the machine tool structures, support, workpiece and machining process. In this paper, the receptance coupling (RC) method was introduced to predict the dynamics of the closed machining system. A milling process was taken for example to predict the chatter limitations using the dynamics of closed model. The mathematical model of the machining system (machine tool structures, spindle, holder and tool), together with the details of joint contacts, was given based on the RC method. The RC model was used to obtain the dynamics of the system, while receptance of the tool point was coupled. Based on the coupling model of the machining system, the depth limitations under different speeds were estimated for the technology parameter optimization in milling process. The response was considered to be the sum of the cutting point and the support system. The flexibility of the support system was considered to be the feedback of the cutting stiffness. By this means, the traditional model was modified to calculate the stability lobe diagram based on the dynamics of the spindle and support system. Furthermore, the milling experiment was carried out to verify the prediction results, and the dominant natural frequencies of receptance at tool point were obtained by modal testing to define the stability lobe diagram. It was found that the chatter results matched well with the stability lobes. It was concluded that the support system with poor stiffness might cause violent chatter especially when the workpiece was thin-walled. The cutting depth limitations of the flexible support system were lower than that of the rigid one. Moreover, this closed model of the machining system is appropriate for the chatter prediction of the flexible support system or thin-walled workpiece, so it is helpful for a better parameter optimization.

The Effect of Cutting Process Parameters on the Stability in Milling

2014 ◽  
Vol 887-888 ◽  
pp. 1200-1204 ◽  
Author(s):  
Te Ching Hsiao ◽  
Shyh Chour Huang
Keyword(s):  
Damping Ratio ◽  
Milling Process ◽  
Material Behavior ◽  
Cutting Process ◽  
Force Model ◽  
Stability Lobe Diagram ◽  
Workpiece Material ◽  
Stability Lobe ◽  
The Stability ◽  
Tool Diameter

In the milling process, the dynamic system in the cutting process is composed of the tool, workpiece, and machine tools themselves. Therefore the mill geometric parameter, workpiece material behavior, and the modal parameters of the cutting system all will influence the stability in milling. Using FLN method and convolution force model to predict the chatter stability of milling process, and discussing the effect of milling parameter on the stability in this article. According to the result: with the increase of the tool diameter, stiffness, damping ratio or the reducing of tangential cutting force coefficient and radial width of cut, the stability lobe diagram tends to move upward. With the increase of natural frequency, the stability lobe diagram tends to move to right side. With the increase of the number of tooth, the stability lobe diagram tends to move downward.

scholarly journals Research of Chatter Suppression in Turning Operation with Process Damping using Stability Lobe Diagram

2019 ◽  
Vol 8 (12S2) ◽  
pp. 539-543
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Modal Testing ◽  
Stability Lobe Diagram ◽  
Diagram Method ◽  
Process Damping ◽  
Chatter Suppression ◽  
Stability Lobe ◽  
The Stability ◽  
The Impact

This paper presents a chatter detection technique based on the stability of the measured Ra and Rz values of process damping and surface roughness in low cutting speed activities. In practice, process damping during machining procedures is hard to predict and identify due to the model and technique of limitation. The impact of cutting conditions on process damping in turning with P20 steel pre-hardened metal in terms of cutting velocity, feed rate and cutting depth was explored by the Stability Lobe Diagram method. A CNC turning machine was used in dry turning procedures with carbide insert. The highest and minimum value of natural frequencies and damping ratios were evaluated by modal testing and the stability lobe diagram analysis was applied. It is concluded that in the same region of the Stability Lobe Diagram, the chatter and measured surface roughness values were correlated and shown to have strong consensus.

scholarly journals Full-Field Operational Modal Analysis of an Aircraft Composite Panel from the Dynamic Response in Multi-Impact Test

Sensors ◽  
2021 ◽  
Vol 21 (5) ◽  
pp. 1602
Author(s):  
Ángel Molina-Viedma ◽  
Elías López-Alba ◽  
Luis Felipe-Sesé ◽  
Francisco Díaz
Keyword(s):  
Modal Analysis ◽  
Energy Absorption ◽  
High Speed ◽  
Operational Modal Analysis ◽  
Modal Identification ◽  
Image Correlation ◽  
Composite Panel ◽  
Impact Excitation ◽  
Full Field ◽  
The Impact

Experimental characterization and validation of skin components in aircraft entails multiple evaluations (structural, aerodynamic, acoustic, etc.) and expensive campaigns. They require different rigs and equipment to perform the necessary tests. Two of the main dynamic characterizations include the energy absorption under impact forcing and the identification of modal parameters through the vibration response under any broadband excitation, which also includes impacts. This work exploits the response of a stiffened aircraft composite panel submitted to a multi-impact excitation, which is intended for impact and energy absorption analysis. Based on the high stiffness of composite materials, the study worked under the assumption that the global response to the multi-impact excitation is linear with small strains, neglecting the nonlinear behavior produced by local damage generation. Then, modal identification could be performed. The vibration after the impact was measured by high-speed 3D digital image correlation and employed for full-field operational modal analysis. Multiple modes were characterized in a wide spectrum, exploiting the advantages of the full-field noninvasive techniques. These results described a consistent modal behavior of the panel along with good indicators of mode separation given by the auto modal assurance criterion (Auto-MAC). Hence, it illustrates the possibility of performing these dynamic characterizations in a single test, offering additional information while reducing time and investment during the validation of these structures.

Discrete Time-Delay Optimal Control Method for Experimental Active Chatter Suppression and Its Closed-Loop Stability Analysis

2019 ◽  
Vol 141 (5) ◽  
Author(s):  
Xingwu Zhang ◽  
Ziyu Yin ◽  
Jiawei Gao ◽  
Jinxin Liu ◽  
Robert X. Gao ◽  
...  
Keyword(s):  
Optimal Control ◽  
Closed Loop ◽  
Control Method ◽  
Trial And Error ◽  
Stability Lobe Diagram ◽  
Weighting Matrix ◽  
Chatter Suppression ◽  
Stability Lobe ◽  
Optimal Control Method ◽  
Discrete Time Delay

Chatter is a self-excited and unstable vibration phenomenon during machining operations, which affects the workpiece surface quality and the production efficiency. Active chatter control has been intensively studied to mitigate chatter and expand the boundary of machining stability. This paper presents a discrete time-delay optimal control method for chatter suppression. A dynamical model incorporating the time-periodic and time-delayed characteristic of active chatter suppression during the milling process is first formulated. Next, the milling system is represented as a discrete linear time-invariant (LTI) system with state-space description through averaging and discretization. An optimal control strategy is then formulated to stabilize unstable cutting states, where the balanced realization method is applied to determine the weighting matrix without trial and error. Finally, a closed-loop stability lobe diagram (CLSLD) is proposed to evaluate the performance of the designed controller based on the proposed method. The CLSLD can provide the stability lobe diagram with control and evaluate the performance and robustness of the controller cross the tested spindle speeds. Through many numerical simulations and experimental studies, it demonstrates that the proposed control method can make the unstable cutting parameters stable with control on, reduce the control force to 21% of traditional weighting matrix selection method by trial and error in simulation, and reduce the amplitude of chatter frequency up to 78.6% in experiment. Hence, the designed controller reduces the performance requirements of actuators during active chatter suppression.

Modelling and simulation of surface topography machined by peripheral milling considering tool radial runout and axial drift

2019 ◽  
Vol 233 (12) ◽  
pp. 2227-2240 ◽  
Author(s):  
Hui-Qun Chen ◽  
Qing-Hui Wang
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Surface Finish ◽  
Dominant Frequency ◽  
Peripheral Milling ◽  
Stability Lobe Diagram ◽  
Vector Operation ◽  
Good Surface ◽  
Stability Lobe ◽  
Feed Mark

Based on the Z-map model of a workpiece and the dynamic cutting forces model of peripheral milling in which the regenerative effect of tool radial runout and axial drift are considered, a model for the prediction of surface topography in peripheral milling operations is presented. According to the stability lobe diagram obtained by the zero-order analytical method, the relationship between spindle speed and surface topography, the tool radial runout, and the axial drift following the chatter are studied. The results show that a stable cutting status but a poor surface finish is obtained at the spindle speeds at which the dominant frequency of the milling system is integral multiples of the selected machining frequency, and a stable cutting status with a good surface finish can be obtained near and on the left side of the resonant spindle speeds determined by the predicted stability lobe diagram. The motion equations of any tooth end mill for peripheral milling are established, and these equations are based on the transformation matrix and the vector operation principle of motion-homogeneous coordinates. In addition, the simulation algorithm and the system of surface topography generated in peripheral milling are given based on the Z-map model. Cutting tests are carried out, and good agreement between the measured surface topographies and the topographies predicted by the model in this study is found in terms of their shape, magnitude, feed mark, profile height of cross-section, and surface roughness. The simulation results show that the milling surface roughness increases with the increase in feed per tooth, which further shows that this simulation system has high credibility. Thus, the simulation and experimental results can provide some practical instructions for the actual peripheral milling in determining the optimal machining conditions.

Research on Modal Analysis of Precision Micro Slitting Turn-Milling Machine Tool Based on Hammer Experimental Method

2019 ◽  
Vol 295 ◽  
pp. 67-72
Author(s):  
Zhong Peng Zheng ◽  
Xin Yang Jiang ◽  
Xin Jin
Keyword(s):  
Machine Tool ◽  
Modal Analysis ◽  
Experimental Method ◽  
Machine Tools ◽  
Processing Parameters ◽  
Milling Machine ◽  
Vibration Model ◽  
Vibration Modal ◽  
Turn Milling ◽  
Machine Structure

In order to improve the dynamic stability of precision micro slitting turn-milling machine tools, reduce or avoid the vibration problem during the cutting process, optimize the machine structure and processing parameters, the modal analysis of precision micro slitting turn-milling machine tool based on hammer experimental method was researched. In this paper, by analyzing the mechanism of precision micro slitting turn-milling machine tools, the multi degree-of-freedom mathematical vibration model of precision slitting turn-milling machine tools is constructed. The precision micro turn-milling machine tool is analyzed based on the hammer experiment analysis. The modal analysis obtained the first five natural frequencies and resonance speeds of the precision micro slitting turn-milling machine tool,including ST26, NN-25UB8K2 and NN-20UB87. The research results show that hammer experimental method can evaluate the vibration modal analysis of precision micro slitting turn-milling machine tools to some extent. The experimental modal analysis results guide and optimize the structural design and processing technology of precision micro slitting turn-milling machine tools.

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