Multi-point Contact Stability Prediction Considering Force-induced Deformation Effect in Milling Thin-Walled Parts

doi:10.3901/JME.2022.17.309

Abstract

Abstract: Thin wall parts have the characteristics of weak rigidity, so it is easy to induce chatter in the machining process. At the same time, the deformation of the workpiece is inevitable due to the existence of milling force. The existence of force-induced deformation leads to the change of radial cutting depth, which leads to the change of start angle and exit angle under milling, and finally affects the stability of machining. At the same time, in the process of side milling, the dynamic parameters of thin-walled parts change obviously along the direction of the cutter axis, so the influence of force-induced deformation and multi-point contact should be taken into account in the establishment of the dynamic model. Firstly, the milling force is modeled and the effect of the spiral angle of the milling cutter is considered. Secondly, an iterative extraction method of deformation is proposed. With the help of workbench software, the workpiece deformation caused by milling force at different axial cutting depths is extracted and fitted. Then, the modal analysis of the workpiece is carried out, the modal vibration mode of the workpiece is extracted and fitted. Finally, the tool-part contact zone is discretized along the tool axis, and the vibration modes and the workpiece deformation caused by milling force at each node are calculated, and a multi-point contact dynamic model considering force-induced deformation is established. Finally, taking titanium alloy (Ti6Al4V) as the research object, the experimental verification is carried out, and compared with the multi-point contact dynamic model without considering force-induced deformation, which proves the superiority of the model proposed in this paper.

Key words: milling chatter, force-induced deformation, multi-point contact, thin-walled parts, titanium alloy

CLC Number:

TH113
TG56

WANG Zhixue, LIU Xianli, LI Maoyue, WANG Lihui, Steven Y. LIANG, YU Fuhang. Multi-point Contact Stability Prediction Considering Force-induced Deformation Effect in Milling Thin-Walled Parts[J]. Journal of Mechanical Engineering, 2022, 58(17): 309-320.

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