{"title":"Chatter Avoidance by Spindle Speed and Orientation Planning in Five-Axis Ball-End Milling of Thin-Walled Blades","authors":"Behnam Karimi, Yusuf Altintas","doi":"10.1115/1.4063654","DOIUrl":null,"url":null,"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.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":2.4000,"publicationDate":"2023-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Manufacturing Science and Engineering-transactions of The Asme","FirstCategoryId":"1085","ListUrlMain":"https://doi.org/10.1115/1.4063654","RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
引用次数: 0
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.
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