A new approach called the``variational theory of complex rays'' (VTCR) is developed for calculating the vibrations of weakly damped elastic structures in the medium-frequency range. Here, the emphasis is put on the most fundamental aspects. The effective quantities (elastic energy, vibration intensity, etc.) are evaluated after solving a small system of equations which does not derive from a finite element discretization of the structure. Numerical examples related to plates show the appeal and the possibilities of the VTCR.
High-speed milling operations of thin walls are often limited by the so-called regenerative effect that causes poor surface finish. The aim of this paper is to examine the link between chatter instability and surface roughness evolution for thin wall milling. Firstly, the linear stability lobes theory for the thin wall milling optimisation was used. Then, in order to consider the modal interactions, an explicit numerical model was developed. The resulting nonlinear system of delay differential equations is solved by numerical integration. The model takes into account the coupling mode, the modal shape, the fact that the tool may leave the cut and the ploughing effect. Dedicated experiments are carried out in order to confirm this modelling. This paper presents surface roughness and chatter frequency measurements. The stability lobes are validated by thin wall milling. Finally, the modal behaviour and the mode coupling give a new interpretation of the complex surface finish deterioration often observed during thin wall milling.
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