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Research Papers

Numerical Analysis of Aeroacoustic Noise for High-Speed Face Milling Cutters in Three Dimensional Unsteady Flow Fields

[+] Author and Article Information
Chunhui Ji

Zhanqiang Liu1

 School of Mechanical Engineering,  Shandong University, Jinan, Shandong 250061, Chinamelius@sdu.edu.cn

1

Corresponding author.

J. Manuf. Sci. Eng 134(4), 041002 (Jun 27, 2012) (9 pages) doi:10.1115/1.4006772 History: Received January 19, 2012; Accepted March 15, 2012; Published June 26, 2012; Online June 27, 2012

Aeroacoustic noise produced by high speed face milling cutters is a serious environmental concern. This paper develops a modeling approach to investigate the aeroacoustic noise generation and propagation by the idling face milling cutters. The approach consists of two parts: (1) an aerodynamic model for evaluating the flow fields based on the Navier–Stokes (N–S) equation and (2) an aeroacoustic model for predicting the acoustic noise by using the Ffowcs Williams and Hawkings (FW–H) equation. Both the steady mode with the multiple reference frames (MRF) model and the unsteady mode with the sliding mesh technique by introducing steady flow variables as its initial fields are simulated. The cutter gullet regions and the insert rake face regions are found to be the primary contributors in noise generation through spectral analysis of noise sources. The acoustic noise in face milling is significantly affected by the cutter diameter and the number of cutter teeth. The noise directivity is found in vertical plane, and the irregular tooth spacing can spread the maximum sound power at the rotating frequency to higher frequencies. In addition, experiments are conducted to measure the acoustic noise from two high speed milling cutters. It is found that the experimental results are generally in good agreement with the simulations.

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Copyright © 2012 by American Society of Mechanical Engineers
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Figures

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Figure 1

Block diagram of numerical simulation of flow and acoustic fields

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Figure 2

Control domain and boundary conditions

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Figure 3

(a) Mesh distribution on the system and (b) unstructured meshes around the cutter

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Figure 11

Overall SPLs for face milling cutters with different diameters

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Figure 12

Overall SPLs for face milling cutters with different tooth numbers

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Figure 13

Sound spectra at 7000 rpm for (a) four-tooth cutter and (b) ten-tooth cutter

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Figure 4

Schematic of the experimental setup

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Figure 5

Velocity and pressure distribution on the surface of cutter 1: (a) the contours of total pressure, (b) the contours of static pressure, (c) the velocity vectors, and (d) isocontour of velocity around the cutter

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Figure 6

Noise spectra of (a) zone A, (b) zone B, (c) zone C, (d) zone D, (e) zone E, and (f) the entire milling cutter

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Figure 7

Noise spectra comparison: (a) cutter 1 and (b) cutter 2

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Figure 8

Noise directivity in horizontal plane at 7000 rpm

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Figure 9

Noise directivity in vertical plane at three speeds

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Figure 10

Spectral plot comparison between cutter 1A and (a) cutter 1B, and (b) cutter 1C

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