Chatter Avoidance by Spindle Speed and Orientation Planning in Five-Axis Ball-End Milling of Thin-Walled Blades

IF 2.4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Journal of Manufacturing Science and Engineering-transactions of The Asme Pub Date : 2023-10-04 DOI:10.1115/1.4063654
Behnam Karimi, Yusuf Altintas
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Abstract

Abstract Selecting suitable cutting conditions is crucial in maintaining chatter stability and achieving acceptable surface quality. However, the selection of a constant set of cutting parameters is not feasible due to the time-varying dynamics of highly flexible thin-walled blades. This paper presents an optimal selection of tool orientation and spindle speed along the tool path as the metal is removed during the ball end milling of blades. The effects of tool orientation and speed on the mechanics and dynamics of the ball-end milling process are formulated. Test case simulations are used to demonstrate the impact of tool orientation and speed on chatter stability and forced vibrations. The proposed algorithm identifies the optimal spindle speed and tool orientation by continuously updating the workpiece dynamics as a function of time and tool position to achieve improved stability and surface quality. Stability simulations are conducted to assess the optimization approach's performance, and the results are compared with experiments by machining a series of thin-walled twisted fan blades.
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薄壁叶片五轴球端铣削中主轴转速和方向规划避免颤振
选择合适的切削条件是保持颤振稳定性和获得满意表面质量的关键。然而,由于高柔性薄壁叶片的时变动力学特性,选择一组恒定的切削参数是不可行的。介绍了刀具球头铣削过程中刀具方向和主轴转速沿刀具轨迹的最佳选择。阐述了刀具方向和速度对球头铣削过程力学和动力学的影响。测试用例模拟用于演示刀具方向和速度对颤振稳定性和强制振动的影响。该算法通过不断更新工件动态作为时间和刀具位置的函数来识别最佳主轴转速和刀具方向,从而提高稳定性和表面质量。通过稳定性仿真来评估优化方法的性能,并与一系列薄壁扭曲风扇叶片的加工实验结果进行了比较。
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来源期刊
CiteScore
6.80
自引率
20.00%
发文量
126
审稿时长
12 months
期刊介绍: Areas of interest including, but not limited to: Additive manufacturing; Advanced materials and processing; Assembly; Biomedical manufacturing; Bulk deformation processes (e.g., extrusion, forging, wire drawing, etc.); CAD/CAM/CAE; Computer-integrated manufacturing; Control and automation; Cyber-physical systems in manufacturing; Data science-enhanced manufacturing; Design for manufacturing; Electrical and electrochemical machining; Grinding and abrasive processes; Injection molding and other polymer fabrication processes; Inspection and quality control; Laser processes; Machine tool dynamics; Machining processes; Materials handling; Metrology; Micro- and nano-machining and processing; Modeling and simulation; Nontraditional manufacturing processes; Plant engineering and maintenance; Powder processing; Precision and ultra-precision machining; Process engineering; Process planning; Production systems optimization; Rapid prototyping and solid freeform fabrication; Robotics and flexible tooling; Sensing, monitoring, and diagnostics; Sheet and tube metal forming; Sustainable manufacturing; Tribology in manufacturing; Welding and joining
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