Adjustment of cutting modes based on the data of numerical simulation of a tool-workpiece system dynamics taking into account resonances
The purpose of the work is to adjust the cutting modes for the manufacturing process of the Cover-Bracket part, which are set in accordance with the recommendations of the electronic catalog CoroPlus ToolGuide by the tool manufacturer Sandvik. This correction is required in order to improve the dynamic stability of machining. The problem of cutting mode adjustment is solved through the use of the methods of numerical simulation of the tool-workpiece system dynamics with regard to the resonances in the Femap engineering analysis program with Nastran. Recommendations are given for cutting modes taking into account the technical capabilities of the machine-tool and tooling, as well as the volume of the material removed with no reference for the dynamic properties of the tool and machine-tool. It is shown that at the 7th and 8th technological transitions the resonant vibrations are observed in the milling tool-workpiece system and the ratio of forces on the cutting edges of milling tools changes up to 245%, which leads to their uneven wear and decreases machining quality. It is found out that the oscillations of the processing forces can be represented as a sum of several harmonics of the rotational and tooth mesh frequencies. The results obtained show that the problem of deviation from the resonant frequencies can be solved not only by lowering the spindle speed, but also by changing the manufacturing process. Recommended change in the sequence of the technological transitions 7 and 8 allows to avoid resonance frequencies without reducing the performance level and machine at the maximum permissible cutter speed of 18,000 rpm. Under this approach, the first harmonics of the tooth mesh frequencies will be outside the resonant zone. In the future, it is planned to supplement the model with the dynamic characteristics of the machine-tool, tool and equipment.