A state-of-art review on chatter and geometric errors in thin-wall machining processes

Wu, Ge; Li, Guangxian; Pan, Wencheng; Izamshah, R.; Xu, Weiwei; Ding, Sheng

doi:10.1016/j.jmapro.2021.05.055

Cited by 63 publications

(24 citation statements)

References 277 publications

(285 reference statements)

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“…Nevertheless, the calculation of the SLDs of parts with low thickness as employed thin plates entails two phenomena. The first one is that the stiffness of the part is lower than the stiffness of the cutting tool, so chatter vibration is mostly affected by the dynamic properties and critical modes of the part [19]. The second phenomenon is the ratio of material removal, which is high compared to the global volume of the part and that leads to a continuous change in its modal parameters and FRF during machining [20].…”

Section: Vibration Monitoring Frf Obtention and Sld Calculationmentioning

confidence: 99%

Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling

et al. 2022

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Thin floor machining is a challenging and demanding issue, due to vibrations that create poor surface quality. Several technologies have been developed to overcome this problem. Ad hoc fixtures for a given part geometry lead to meeting quality tolerances, but since they lack flexibility, they are expensive and not suitable for low manufacturing batches. On the contrary, flexible fixtures consisting of vacuum cups adaptable to a diversity of part geometries may not totally avoid vibrations, which greatly limits its use. The present study analyses the feasibility of thin floor milling in terms of vibration and roughness, in the cases where milling is conducted without back support, a usual situation when flexible fixtures are employed, so as to define the conditions for a stable milling in them and thus avoid the use of ad hoc fixtures. For that purpose, the change of modal parameters due to material removal and its influence on chatter appearance have been studied, by means of stability lobe diagrams and Fourier Transform analysis. Additionally, the relationship between surface roughness and chatter frequency, tooth passing frequency, and spindle frequency have been studied. Ploughing effect has also been observed during milling, and the factors that lead to the appearance of this undesirable effect have been analyzed, in order to avoid it. It has been proven that finish milling of thin floors without support in the axial direction of the mill can meet aeronautic tolerances and requirements, providing that proper cutting conditions and machining zones are selected.

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Section: Vibration Monitoring Frf Obtention and Sld Calculationmentioning

confidence: 99%

Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling

et al. 2022

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“…Improper clamping can seriously affect the final quality of the machined surface, especially the accuracy of the shape. This issue is particularly important when machining thin-walled components, as highlighted in the study by Wu et al [ 9 ].…”

Section: Introductionmentioning

confidence: 99%

Influence of the Milling Conditions of Aluminium Alloy 2017A on the Surface Roughness

et al. 2022

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The article presents the results and process analysis of the face milling of aluminium alloy 2017A with the CoroMill 490 tool on an AVIA VMC 800 vertical milling centre. The study analysed the effects of the cutting speed, the feed rate, the actual number of teeth involved in the process, the minimum thickness of the cut layer (hmin), and the relative displacement in the tool-workpiece system D(ξ) on the surface roughness parameter Ra. To measure relative displacement, an original bench was used with an XL-80 laser interferometer. The analysis of relative displacement and surface roughness allowed these factors to be correlated with each other. The purpose of this article is to determine the stable operating ranges of the CoroMill 490-050Q22-08M milling head with respect to the value of the generated relative displacement w during the face-milling process and to determine its influence on surface roughness. The research methodology presented in this paper and the cutting tests carried out allowed the determination of the optimum operating parameters of the CoroMill 490-050Q22-08M tool during the face milling of aluminium alloy 2017A, which are vc 300 m/m and fz—0.14 mm/tooth. Working with the defined cutting parameters allows all the cutting inserts in the tool body to be involved in shaping the geometrical structure of the surface, while maintaining a low vibration level D(ξ) > 1 µm, a low value of the parameter hmin > 1.5 µm, and the desired value of the parameter Ra > 0.2 µm

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“…A variety of works have been completed to model the magnitudes of this deflection, but typically ranges from 0.01 mm to 0.3 mm in size [1][2][3]. Additionally, the low stiffness of the wall itself readily results in chatter regardless of tool stiffness [4,5]. Chatter leads to a poor surface finish on the machined wall and reduced tool life.…”

Section: Introductionmentioning

confidence: 99%

Implementation of Sacrificial Support Structures for Hybrid Manufacturing of Thin Walls

Vaughan

Saldaña

Nycz

2022

JMMP

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Thin-walled features can be difficult to produce with traditional machining methods which often rely on excess stock material for stiffness. This challenge is increased in hybrid manufacturing where the feature is already near net shape before machining. Significant workpiece deflection can result in poor geometric and surface finish tolerances on the finished part. A potential solution to this problem is to implement sacrificial support structures to the as-printed geometry. The supports are then machined away during the finishing portion of the hybrid process. In the present work, several different design parameters for these sacrificial supports were evaluated to determine their impact on the quality of representative thin wall geometry samples. The angle, height, and spacing of triangular support structures were varied for each sample and then machined and examined. The addition of these supports relative to an unsupported configuration provided a deflection reduction of around 0.2 mm. Surface roughness was improved by approximately 1.5 µm. Increasing values of support height were found to correspond to reduced wall deflection. Similarly, decreasing values of support angle and support spacing improved geometric accuracy. Efficiency comparisons showed that increases in print time corresponded to rapidly diminishing gains in geometric accuracy but continued to improve surface roughness. Implications for hybrid finishing of additively manufactured thin-walled structures is briefly discussed.

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A state-of-art review on chatter and geometric errors in thin-wall machining processes

Cited by 63 publications

References 277 publications

Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling

Influence of Axial Depth of Cut and Tool Position on Surface Quality and Chatter Appearance in Locally Supported Thin Floor Milling

Influence of the Milling Conditions of Aluminium Alloy 2017A on the Surface Roughness

Implementation of Sacrificial Support Structures for Hybrid Manufacturing of Thin Walls

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