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Research Papers

Time-Varying Chatter Frequency Characteristics in Thin-Walled Workpiece Milling With B-Spline Wavelet on Interval Finite Element Method

[+] Author and Article Information
Chenxi Wang

State Key Laboratory for Manufacturing Systems Engineering,
Xi’an Jiaotong University,
Xi'an, Shaanxi 710049, China;
School of Mechanical Engineering,
Xi'an Jiaotong University,
Xi'an, Shaanxi 710049, China
e-mail: wangchenxi@stu.xjtu.edu.cn

Xingwu Zhang

Associate Professor
State Key Laboratory for Manufacturing Systems Engineering,
Xi'an Jiaotong University,
Xi'an, Shaanxi 710049, China;
School of Mechanical Engineering,
Xi'an Jiaotong University,
Xi'an, Shaanxi 710049, China
e-mail: xwzhang@mail.xjtu.edu.cn

Xuefeng Chen

Professor
State Key Laboratory for Manufacturing Systems Engineering,
Xi'an Jiaotong University,
Xi'an, Shaanxi 710049, China;
School of Mechanical Engineering,
Xi'an Jiaotong University,
Xi'an, Shaanxi 710049, China
e-mail: chenxf@mail.xjtu.edu.cn

Hongrui Cao

Professor
State Key Laboratory for Manufacturing Systems Engineering,
Xi'an Jiaotong University,
Xi'an, Shaanxi 710049, China;
School of Mechanical Engineering,
Xi'an Jiaotong University,
Xi'an, Shaanxi 710049, China
e-mail: chr@mail.xjtu.edu.cn

1Corresponding author.

Manuscript received October 7, 2018; final manuscript received March 13, 2019; published online April 1, 2019. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 141(5), 051008 (Apr 01, 2019) (8 pages) Paper No: MANU-18-1712; doi: 10.1115/1.4043257 History: Received October 07, 2018; Accepted March 14, 2019

As the most significant material removal method, milling plays a very important role in the manufacturing industry. However, chatter occurs frequently in milling, which will seriously affect the production efficiency. The accurate prediction of chatter frequency can contribute to chatter monitoring and the design of the controller for chatter mitigation. During thin-walled workpiece milling under chatter, a new phenomenon of time-varying chatter frequency is discovered and explained in this paper. This phenomenon can be explained as follows, with the workpiece material removal, the modal parameters change during thin-walled milling, which can cause the continuous change of chatter frequency. In order to predict the varying modal parameters, this paper provided an efficient tool, the B-spline wavelet on interval finite element method (BSWIFEM), which can possess the material removal problem more accurately and more rapidly. Based on the calculated modal parameters, the time-varying chatter frequency can be obtained with the chatter frequency calculation formulas. To verify the calculated results, a number of milling tests are implemented on thin-walled parts. The experimental results show that the calculated chatter frequency is in good agreement with the measured chatter frequency, which validates the effectiveness of the proposed method.

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Figures

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Fig. 1

Tensor product BSWI scaling functions Φ = Φ1 ⊗ Φ2

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Fig. 2

Rectangle elemental solving domain Ωe and layout of nodes DOFs

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Fig. 3

Solving domain for BSWI43 Mindlin plate and layout of nodes DOFs

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Fig. 4

The workpiece and impact test setup

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Fig. 5

The diagram of the selected thin-walled workpiece

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Fig. 6

The first six natural frequencies at different tool positions

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Fig. 7

(a) The real workpiece in milling and (b) the virtual workpiece in simulation

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Fig. 8

Milling force measuring setup

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Fig. 9

The setup of milling experiment

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Fig. 10

The acceleration signals in the time domain

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Fig. 11

The acceleration signals in the frequency domain

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Fig. 12

The time-frequency plane of acceleration signals

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Fig. 13

(a) The measured and predicted chatter frequencies and (b) the relative error

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