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Research Papers

High-Quality Machining of Edges of Thin-Walled Plates by Tilt Side Milling Based on an Analytical Force-Based Model

[+] Author and Article Information
Gongyu Liu

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

Jiaqiang Dang

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

Weiwei Ming

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

Qinglong An

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

Ming Chen

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

Haonan Li

Faculty of Science and Engineering, School of Aerospace,
University of Nottingham Ningbo China,
Ningbo 315100, China
e-mail: Haonan.Li@nottingham.edu.cn

1Corresponding author.

Manuscript received December 7, 2018; final manuscript received March 25, 2019; published online April 19, 2019. Assoc. Editor: Guillaume Fromentin.

J. Manuf. Sci. Eng 141(6), 061008 (Apr 19, 2019) (12 pages) Paper No: MANU-18-1849; doi: 10.1115/1.4043363 History: Received December 07, 2018; Accepted March 27, 2019

The milling of thin-walled workpieces is a common process in many industries. However, the machining defects are easy to occur due to the vibration and/or deformation induced by the poor stiffness of the thin structures, particularly when side milling the edges of plates. To this problem, an attempt by inclining the tool to a proper tilt angle in milling the edges of plates was proposed in this paper, in order to decrease the cutting force component along the direction of the lowest stiffness of the plates, and therefore to mitigate the machining vibration and improve the machined surface quality effectively. First, the milling force model in consideration of the undeformed chip thickness and the tool-workpiece engagement (TWE) was introduced in detail. Then, a new analytical assessment model based on the precisely established cutting force model was developed so as to obtain the optimum tool tilt angle for the minimum force-induced defects after the operation. Finally, the reliability and correctness of the theoretical force model and the proposed assessment model were validated by experiments. The methodology in this paper could provide practical guidance for achieving high-quality machined surface in the milling operation of thin-walled workpieces.

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Figures

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Fig. 1

Flowchart of the analytical force model in the tilt side milling of edges of thin-walled workpiece

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Fig. 2

Schematics of the force modeling in the side milling process of edges of thin-walled workpiece: (a) the instantaneous milling element on the tool edge, (b) the view along the Zt-axis direction, (c) the injection of the elemental milling forces to the TECS (PX1Y1Z1 in the figure), and (d) the coordinate transformation of the elemental milling forces from the TECS to the TCS (OtXtYtZt in the figure)

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Fig. 3

Schematics of the undeformed chip thickness in the side milling of edges of thin-walled workpiece

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Fig. 4

(a) Calculation of the TWE in the side milling of edges of thin-walled workpiece and (b) the expanded drawing of the TWE boundaries

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Fig. 5

Flowchart for computing the optimal tool tilt angle based on the Golden Section Search method

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Fig. 6

(a) Experimental setup and the employed two configurations used in the experiments, (b) the first one having the cantilever length of 80 mm and (c) the second one having the cantilever length of 8 mm

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Fig. 7

Comparisons of the experimental and theoretical cutting forces at (a) tool tilt angle θ = 30 deg and (b) θ = 50 deg

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Fig. 8

Comparison of the experimental and theoretical values of the maximum Fx, Fy, and Fz at different tool tilt angles

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Fig. 9

Comparison of the experimental and theoretical values of the average Fx, Fy, and Fz at different tool tilt angles (only in the cutting period)

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Fig. 10

Illustration of the tool tilt angle and theoretical cutting forces of Fx, Fy, and Fz at (a) ae = 0.1 mm, (b) ae = 0.2 mm, and (c) ae = 0.3 mm

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Fig. 11

Variation of index f of the assessment model and (b) variation of the cutting force component Fz, at ae = 0.1 mm

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Fig. 12

Machined surface roughness at different tilt angles

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Fig. 13

Machined surface topographies at different tool tilt angles

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Fig. 14

Instantaneous vibration displacement of the plate at tool tilt angles 10 deg

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Fig. 15

Variations of the vibration amplitude and the assessment index f with the tool tilt angle

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