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Research Papers

Stability Prediction and Step Optimization of Trochoidal Milling

[+] Author and Article Information
Rong Yan

National NC System Engineering
Research Center,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: yanrong@hust.edu.cn

Hua Li

National NC System Engineering
Research Center,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: M201570333@hust.edu.cn

Fangyu Peng

National NC System Engineering
Research Center,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China;
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: zwm8917@263.net

Xiaowei Tang

National NC System Engineering
Research Center,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: txwysxf@126.com

Jiawei Xu

National NC System Engineering
Research Center,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: M201570600@hust.edu.cn

Haohao Zeng

National NC System Engineering
Research Center,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430074, China
e-mail: mzh2012@hust.edu.cn

1Corresponding author.

Manuscript received December 19, 2016; final manuscript received May 10, 2017; published online June 22, 2017. Assoc. Editor: Satish Bukkapatnam.

J. Manuf. Sci. Eng 139(9), 091006 (Jun 22, 2017) (11 pages) Paper No: MANU-16-1659; doi: 10.1115/1.4036784 History: Received December 19, 2016; Revised May 10, 2017

When machining narrow grooves, corners, and other complex cavities with trochoidal milling, the irrationally large trochoidal step usually leads to chatter, while the conservative trochoidal step constrains the machining efficiency. In this paper, a stability prediction model of trochoidal milling is established to solve these problems. An approach considering trochoidal steps and spindle speeds is presented to predict stability boundary of trochoidal milling. With considering the varying cutter-workpiece engagements, the stability of trochoidal milling process is predicted by obtaining the stability lobes of different cutter location (CL) points along the trochoidal milling tool paths. Based on the proposed stability model, a trochoidal step optimization strategy is developed to improve the machining efficiency of trochoidal milling under other parameters in a given situation. Cutting experiments are performed on the machining center GMC 1600H/2 to show the effectiveness of the proposed trochoidal milling stability model. Finally, simulations are adopted to illustrate the optimization strategy.

Copyright © 2017 by ASME
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References

Figures

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Fig. 1

Trochoidal milling tool paths

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Fig. 2

Trochoidal milling geometric model

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Fig. 3

The exit angle when the cutting tool moving in the line segment (φst=θ=0): (a) Rs≤R and (b)  Rs>R

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Fig. 4

The start angle and the exit angle when the cutting tool moving in the arc segment (φst=θ): (a)  Rs>R and (b) Rs≤R

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Fig. 5

Dynamic model of milling system

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Fig. 6

The flowchart of stability prediction of trochoidal milling

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Fig. 7

The stability lobe diagrams at different CL points

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Fig. 8

The stability limit based on different the radius of revolution of tool (r)

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Fig. 9

Modal impact experiments

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Fig. 10

Frequency response function of tool tip

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Fig. 11

Comparison between predicted and measured cutting forces (n = 2000 rpm, f = 400 mm/min, ae = 4 mm, ap = 2 mm)

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Fig. 12

Stability lobe diagram of trochoidal milling

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Fig. 13

Verification experiment of trochoidal milling stability

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Fig. 14

(a) Frequency spectrum analysis of the cutting force at point A (stable), (b) frequency spectrum analysis of the cutting force at point B (chatter), (c) frequency spectrum analysis of the cutting force at point C (stable), (d) frequency spectrum analysis of the cutting force at point D (chatter), (e) frequency spectrum analysis of the cutting force at point E (stable), and (f) frequency spectrum analysis of the cutting force at point F (stable)

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Fig. 15

Stability lobe diagram of trochoidal milling based on step (a: Str = 3.4 mm, b: Str = 4.3 mm, and c: Str = 4.9 mm)

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Fig. 16

Cavity of trochoidal milling: (a) Str = 3.4 mm, (b) Str = 4.3 mm, and (c) Str = 4.9 mm

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