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Research Papers

Dynamics and Stability Prediction of Five-Axis Flat-End Milling

[+] Author and Article Information
YaoAn Lu

State Key Laboratory of
Mechanical System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: luyaoan028@163.com

Ye Ding

State Key Laboratory of
Mechanical System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: y.ding@sjtu.edu.cn

LiMin Zhu

State Key Laboratory of
Mechanical System and Vibration,
School of Mechanical Engineering,
Shanghai Jiao Tong University,
Shanghai 200240, China
e-mail: zhulm@sjtu.edu.cn

1Corresponding author.

Manuscript received August 19, 2016; final manuscript received December 4, 2016; published online February 8, 2017. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 139(6), 061015 (Feb 08, 2017) (11 pages) Paper No: MANU-16-1453; doi: 10.1115/1.4035422 History: Received August 19, 2016; Revised December 04, 2016

The tool orientation of a flat-end cutter, determined by the lead and tilt angles of the cutter, can be optimized to increase the machining strip width. However, few studies focus on the effects of tool orientation on the five-axis milling process stability with flat-end cutters. Stability prediction starts with cutting force prediction, and the cutting force prediction is affected by the cutter-workpiece engagement (CWE). The engagement geometries occur between the flat-end cutter and the in-process workpiece (IPW) are complicated in five-axis milling, making the stability analysis for five-axis flat-end milling difficult. The robust discrete vector method (DVM) is adopted to identify the CWE for flat-end millings, and it can be extended to apply to general cutter millings. The milling system is then modeled as a two-degrees-of-freedom spring-mass-damper system with the predicted cutting forces. Thereafter, a general formulation for the dynamic milling system is developed considering the regenerative effect and the mode coupling effect simultaneously. Finally, an enhanced numerical integration method (NIM) is developed to predict the stability limits in flat-end milling with different tool orientations. Effectiveness of the strategy is validated by conducting experiments on five-axis flat-end milling.

Copyright © 2017 by ASME
Topics: Stability , Cutting , Milling
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Figures

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Fig. 1

Local, cutter, and work coordinate systems

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Fig. 2

Discrete vector method and cutting simulation

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Fig. 3

The projection of the tool surface and the workpiece surface on the xy plane

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Fig. 4

Schematic of intersection point determination in the CCS

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Fig. 5

Schematic of FCS (a) the boundary partition of a cutter surface and (b) feasible contact surface

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Fig. 6

Intersection points, envelope boundaries, and FCS

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Fig. 7

Cutter-workpiece engagement: (a) engagement region, (b) engagement region in cutter surface, and (c) ϕ–z plane

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Fig. 8

Illustration of a dynamic milling system

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Fig. 9

Convergence of the eigenvalues with different NIMs for the milling system with a straight flute cutter

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Fig. 10

Convergence of the eigenvalues with different NIMs for the milling system with a helical flute cutter

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Fig. 11

Tests setup: (a) setup in cutting test and (b) impact test

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Fig. 12

Frequency response functions of the machine-tool system: (a) Hxx, (b) Hyy, and (c) Hyx

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Fig. 13

Schematic of the tool path in the cutting experiments

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Fig. 14

The computed SLD and the experimental results with tilt angle ω=0 deg. The symbols are classified as follows: o is stable milling status; x is unstable milling status; Δ is not clearly stable or unstable.

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Fig. 15

Cutting forces, force spectrums, and finished surfaces for the selected parameter points A, B, C, and D in Fig. 14: (a) point A (7600 rpm, 0 deg) and point C (6200 rpm, 10 deg) and (b) point B (7000 rpm, 0 deg) and point D (7000 rpm, 5 deg)

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Fig. 16

The computed SLD and the experimental results with lead angle λ=5 deg. The symbols are classified as follows: o is stable milling status; x is unstable milling status; Δ is not clearly stable or unstable.

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