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Research Papers

Tool Point Frequency Response Prediction for Micromilling by Receptance Coupling Substructure Analysis

[+] Author and Article Information
Lu Xiaohong, Zhang Haixing, Liu Shengqian

Key Laboratory for Precision and Non-traditional
Machining Technology of Ministry of Education,
Dalian University of Technology,
No. 2 LingGong Road,
Dalian, LiaoNing 116026, China

Jia Zhenyuan

Key Laboratory for Precision and Non-traditional
Machining Technology of Ministry of Education,
Dalian University of Technology,
No. 2 LingGong Road,
Dalian, LiaoNing 116026, China
e-mail: jzyxy@dlut.edu.cn

Feng Yixuan, Steven Y. Liang

The George W. Woodruff School of
Mechanical Engineering,
Georgia Institute of Technology,
Atlanta, GA 30332-0405

1Corresponding author.

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

J. Manuf. Sci. Eng 139(7), 071004 (Mar 08, 2017) (13 pages) Paper No: MANU-16-1454; doi: 10.1115/1.4035491 History: Received August 19, 2016; Revised December 08, 2016

One of the challenges in micromilling processing is chatter, an unstable phenomenon which has a larger impact on the microdomain compared to macro one. The minimization of tool chatter is the key to good surface quality in the micromilling process, which is also related to the milling tool and the milling structure system dynamics. Frequency response function (FRF) at micromilling tool point describes dynamic behavior of the whole micromilling machine-spindle-tool system. In this paper, based on receptance coupling substructure analysis (RCSA) and the consideration of rotational degree-of-freedom, tool point frequency response function of micromilling dynamic system is obtained by combining two functions calculated from beam theory and obtained by hammer testing. And frequency response functions solved by Timoshenko's and Euler's beam theories are compared. Finally, the frequency response function is identified as the modal parameters, and the modal parameters are transformed into equivalent structural parameters of the physical system. The research work considers the difference of theoretical modeling between the micromilling and end-milling tool and provides a base for the dynamic study of the micromilling system.

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References

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Figures

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Fig. 1

Rigid connection in receptance coupling

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Fig. 2

Receptance coupling applied to acquire cutter point frequency response function

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Fig. 3

Coordinate graph of the uniform beam with uniform cross section

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Fig. 4

The system of micromilling machine-spindle-tool

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Fig. 5

Dimensions of micromilling tool

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Fig. 6

The scanning electron microscope photo of micromilling tool's end

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Fig. 7

Experiments for acquiring tool point frequency response function using receptance coupling

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Fig. 8

Measuring system of frequency response function

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Fig. 9

Frequency response function of substructure B in y direction

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Fig. 10

Displacement frequency response at the end 1 of substructure B in y direction

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Fig. 11

Frequency response function at point 1 of substructure B in x direction (a) Frequency response function hB11fM and (b) Frequency response function hB11MM

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Fig. 12

Frequency response function at point 1 of substructure B in y direction (a) Frequency response function hB11fM and (b) Frequency response function hB11MM

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Fig. 13

Comparison between measurement and calculation of HC11(1,1) in x direction

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Fig. 14

Comparison between measurement and calculation of HC11(1,1) in y direction

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Fig. 15

Computation of substructure A of micromilling tool

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Fig. 16

Tool point frequency response of micromilling system in y direction

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Fig. 17

Tool point frequency response function of micromilling system in x direction

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