Analysis and Research of the Vibration of the High-Speed Cutting Process

2011 ◽  
Vol 188 ◽  
pp. 642-647
Author(s):  
A.M. Tang ◽  
Z.X. Zhou ◽  
W.W. Huang
Keyword(s):  
Analytical Model ◽  
High Speed ◽  
End Milling ◽  
Milling Process ◽  
Cutting Process ◽  
Stable Region ◽  
High Speed Cutting ◽  
Dynamic Cutting Force ◽  
The Stability ◽  
End Milling Process

The paper takes the dynamic cutting process as research subject to analyze and research the high-speed milling process. Through carrying out the dynamical modeling and simulation of the milling process, the analytical model of the dynamic cutting force and the chatter stable region of the spiral end mill were established. On the basis of the analytical model, the simulation of the end milling process was carried out, and the interpretational domain of the simulation was confirmed experimentally. Finally, the parameter optimization of the high-speed cutting process was investigated in the term of the stability of the cutting process.

Dynamic cutting force prediction for micro end milling considering tool vibrations and run-out

2018 ◽  
Vol 233 (7) ◽  
pp. 2248-2261 ◽  
Author(s):  
Xuewei Zhang ◽  
Tianbiao Yu ◽  
Wanshan Wang
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
End Milling ◽  
Chip Thickness ◽  
Milling Process ◽  
Force Model ◽  
Dynamic Cutting Force ◽  
Micro End Milling ◽  
Tool Vibrations ◽  
End Milling Process

An accurate prediction of cutting forces in the micro end milling, which is affected by many factors, is the basis for increasing the machining productivity and selecting optimal cutting parameters. This paper develops a dynamic cutting force model in the micro end milling taking into account tool vibrations and run-out. The influence of tool run-out is integrated with the trochoidal trajectory of tooth and the size effect of cutting edge radius into the static undeformed chip thickness. Meanwhile, the real-time tool vibrations are obtained from differential motion equations with the measured modal parameters, in which the process damping effect is superposed as feedback on the undeformed chip thickness. The proposed dynamic cutting force model has been experimentally validated in the micro end milling process of the Al6061 workpiece. The tool run-out parameters and cutting forces coefficients can be identified on the basis of the measured cutting forces. Compared with the traditional model without tool vibrations and run-out, the predicted and measured cutting forces in the micro end milling process show closer agreement when considering tool vibrations and run-out.

Predictive Model of Surface Roughness in High-Speed End Milling Process by Factorial Design of Experiments

2007 ◽  
Vol 339 ◽  
pp. 189-194
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao
Keyword(s):  
Surface Roughness ◽  
Design Of Experiments ◽  
Factorial Design ◽  
High Speed ◽  
End Milling ◽  
Milling Process ◽  
Regression Coefficients ◽  
Milling Parameters ◽  
Factorial Design Of Experiments ◽  
End Milling Process

Predictive models are presented for the surface roughness in high-speed end milling of 0.45%C steel and P20 die-mould steel based on statistical test and multiple-regression analysis. The data for establishing model is derived from experiments conducted on a high-speed machining centre by factorial design of experiments. The significances of the regression equation and regression coefficients are tested in this paper. The effects of milling parameters on surface roughness are investigated by analyzing the experimental curves.

Simulation of End Milling for Weak-Rigidity Structural Parts of Aluminium Alloy in Aviation

2011 ◽  
Vol 201-203 ◽  
pp. 332-336
Author(s):  
Chun Lin Fu ◽  
Cong Kang Wang ◽  
Tie Gang Li ◽  
Wan Shan Wang
Keyword(s):  
High Speed ◽  
End Milling ◽  
Element Model ◽  
Milling Process ◽  
Milling Force ◽  
Drilling Tool ◽  
Structural Parts ◽  
Aluminum Alloy 7075 ◽  
End Milling Process ◽  
Lower Material

To resolve the problem of the parts deformation because of the milling force, a finite element model (FEM) of end milling process simulation in milling force field was established. On the base of FEM, we simulate the high-speed end milling type structure of aluminum alloy 7075 parts. We successfully predict the end milling force, obtain the effect between the upper and lower material to the milling force, and Mises stress and the tool length beyond the part.The simulation results show that the lower material can increase the milling force to upper, and upper material can decrease milling force to lower layer.The drilling tool length beyond the part is about 0.5 mm .

Simulation of Three-Dimensional Dynamic Cutting Forces and Chatter Stability in Ball-End Milling

2010 ◽  
Vol 443 ◽  
pp. 302-307
Author(s):  
Jun Zhao ◽  
Xiao Feng Zhang ◽  
Han Bing Luo
Keyword(s):  
High Speed ◽  
End Milling ◽  
Three Dimensional ◽  
Milling Process ◽  
Ball End Milling ◽  
Parameters Selection ◽  
Nonlinear Dynamics Model ◽  
Dynamic Components ◽  
The Stability ◽  
Milling Forces

By taking into account the regenerative chatter vibration, a nonlinear dynamics model for high speed ball-end milling is proposed. The effect of dynamic components of milling forces on chatter is analyzed. A method to predict the stability limits of high speed ball-end milling process is proposed and the stability lobes diagram is simulated. The comparison of experimental milling forces with the simulation results indicates the high accuracy of the model and the effectiveness of the simulation algorithms. The proposed method provides a theoretical instruction for parameters selection and optimization in milling processing.

Machining Characteristics of AlN-hBN Composites in End-Milling and Precision Lapping Processes

2008 ◽  
Vol 368-372 ◽  
pp. 947-950
Author(s):  
Si Young Beck ◽  
Bong Cheol Shin ◽  
Myeong Woo Cho ◽  
Eun Sang Lee ◽  
Dong Sam Park ◽  
...  
Keyword(s):  
Material Properties ◽  
End Milling ◽  
Milling Process ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Micro Cracks ◽  
Experimental Works ◽  
Machining Characteristics ◽  
End Milling Process

In this study, the machining characteristics of developed AlN-hBN composites were investigated in the end-milling and precision lapping processes. To achieve the objectives, material properties of the developed AlN-hBN composites were evaluated according to the variation of hBN contents. And, required experimental works were performed to investigate the machining characteristics of the composites. First, the machiniability of the composite was evaluated in the end-milling process under various cutting conditions, such as spindle speed, feederate, and depth of cut variations. Also, generated micro cracks caused by the cutting process were investigated via SEM photographs. Next, precision lapping experiments were performed under various conditions, and the results were estimated.

Mode Coupling Behavior in End Milling

2009 ◽  
Author(s):  
C. Y. Huang ◽  
J.-J. Junz Wang
Keyword(s):  
Mode Coupling ◽  
End Milling ◽  
Milling Process ◽  
Chatter Vibration ◽  
Rotation Direction ◽  
Coupling Behavior ◽  
Structure Vibration ◽  
The Stability ◽  
Milling Dynamics ◽  
End Milling Process

Chatter is caused by two main mechanisms: the regenerative waviness and the mode coupling. Both of these two chatter mechanisms always exist simultaneously, but most studies only discuss the regenerative chatter behavior. The purpose of this paper is to investigate the mode coupling behavior in end milling process. A mechanical model considering both of the regenerative and mode coupling effects is then constructed to simulate the milling dynamics. It is shown that the stability of milling is dominated by the eigenvalues of the process matrix and the structure vibration trajectories are affected by the eigenvectors of the process matrix. The rotation direction of chatter vibration is an important feature to determine whether mode coupling chatter occurs or not. By analyzing vibration trajectories, this paper then shows that chatter vibration will rotate in the direction which periodically accumulates the vibration energy. Finally, some methods for adjusting the cutting conditions to avoid the mode coupling chatter are proposed.

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