An efficient decomposition-condensation method for chatter prediction in milling large-scale thin-walled structures

Yang, Yun; Zhang, Weihong; Ma, Yingchao; Wan, Min; Dang, Xue-Bin

doi:10.1016/j.ymssp.2018.11.013

Cited by 61 publications

(21 citation statements)

References 48 publications

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“…At high cutting speeds, intense shear takes place so rapidly that the contact between neighboring segments reduces and tends to vanish until the discontinuous chips are formed [17]. This instability causes fluctuation of cutting force and thus vibration or even chatter [40] in the metal cutting process, which limit the material removal rate, degrade the surface finish and reduce the tool life [28,[41][42][43][44]. For these reasons, a number of researchers have investigated the formation mechanism of chips to seek a balanced solution.…”

Section: Associated Problemsmentioning

confidence: 99%

Chip Formation Mechanism of Inconel 718: A Review of Models and Approaches

Liu

Wan

Zhang

et al. 2021

Chin. J. Mech. Eng.

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Inconel 718, a nickel, chrome and iron alloy, has special advantages, such as high-temperature strength, thermal resistance and corrosion resistance, which facilitate wide usage in the aerospace industry, especially in the hot sections of gas turbine engines. However, machining this alloy is correlated closely with the material’s inherent properties such as excellent combination of strength, hardness and toughness, low thermal conductivity and the tendency to adhere to cutting tools. This nickel alloy also contains inclusions of hard abrasive carbide particles that lead to work-hardening of the workpiece material and thus abrasive wear of the cutting tool. That is, the machining of Inconel 718 is always influenced by high mechanical and thermal loads. This article reviews the chip formation mechanism of Inconel 718. One of the main characteristics in machining of Inconel 718 is that it will produce serrated or segmented chips in a wide range of cutting speeds and feeds. Existing studies show that the chip serration or segmentation by shear localization affects the machined surface integrity, and also contributes to the chip’s evacuation and the automation of machining operations. Thus, research conclusion indicates that the serrated or segmented chip phenomenon is desirable in reducing the level of cutting force, and detailed analysis of models and approaches to understand the chip formation mechanism of Inconel 718 is vital for machining this alloy effectively and efficiently. Therefore, this article presents some summaries on the models and approaches on the chip formation in machining of Inconel 718.

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Section: Associated Problemsmentioning

confidence: 99%

Chip Formation Mechanism of Inconel 718: A Review of Models and Approaches

Liu

Wan

Zhang

et al. 2021

Chin. J. Mech. Eng.

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“…They are used as inputs for the initial conditions of the workpiece. Then, self-developed or commercial software such as ANSYSTM [20,24,34,71] or ABAQUS [29,35,53,58,71,150] are used to obtain the FRF of the system, the dynamic behavior or its deflection.…”

Section: Computational Solutionsmentioning

confidence: 99%

“…Tuysuz and Altintas [57] developed an iterated improved reduction system technique combined with a matrix perturbation technique to use the computational time only once. Yang et al [29] used component mode synthesis (CMS) and space structural modification to develop a decomposition-condensation model that reduce computational time. Fei et al [20] solved the dynamic model using a semi-discretization method.…”

Section: Computational Solutionsmentioning

confidence: 99%

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

et al. 2019

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Thin-wall parts are common in the aeronautical sector. However, their machining presents serious challenges such as vibrations and part deflections. To deal with these challenges, different approaches have been followed in recent years. This work presents the state of the art of thin-wall light-alloy machining, analyzing the problems related to each type of thin-wall parts, exposing the causes of both instability and deformation through analytical models, summarizing the computational techniques used, and presenting the solutions proposed by different authors from an industrial point of view. Finally, some further research lines are proposed.

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“…In aircraft, thin walls are included in the design of fuselage, control surface, on-board equipment and body, etc. [ 1 , 2 , 3 ].…”

Section: Introductionmentioning

confidence: 99%

“…In aircraft, thin walls are included in the design of fuselage, control surface, on-board equipment and body, etc. [1][2][3]. Increasingly frequently, the term "integral (structural) thin-walled elements" is used.…”

Section: Introductionmentioning

confidence: 99%

Techniques for Thin-Walled Element Milling with Respect to Minimising Post-Machining Deformations

et al. 2020

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The paper examines the impact of selected machining techniques and the semi-finished product technological history on deformations of thin-walled elements made of EN AW-2024 T351 aluminium alloy after milling. The following techniques have been implemented: High Performance Cutting, High Speed Cutting, conventional finishing (CF) and combinations of these techniques. As for the semi-finished product technological history, the rolling direction has been analysed. It has been assumed that it can be relevant in relation to the cutting tool feed direction and, in consequence, exert considerable impact on the stress, as well as deformation following machining. The interest in this issue proceeds from significant challenges faced by the industry, particularly in the aerospace sector. The analysis of results obtained has shown that milling in the direction perpendicular to the rolling direction results in larger deformations than milling in the parallel direction. Additionally, it has been revealed that applying a correctly selected machining technique makes it possible to minimise post-machining deformations of thin-walled elements.

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An efficient decomposition-condensation method for chatter prediction in milling large-scale thin-walled structures

Cited by 61 publications

References 48 publications

Chip Formation Mechanism of Inconel 718: A Review of Models and Approaches

Chip Formation Mechanism of Inconel 718: A Review of Models and Approaches

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

Techniques for Thin-Walled Element Milling with Respect to Minimising Post-Machining Deformations

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