An improved dynamics modeling during milling of the thin-walled parts based on magnetorheological damping fixture

Abstract

Aerospace thin-walled parts vibrates during the process of milling due to their characteristics of low rigidity, which influences the machining quality of the workpiece. Based on the characteristics of magnetorheological fluid excitation solidification, a magnetorheological damping fixture is designed to semi-actively suppress the vibration generated during the machining process. This paper simplifies the multi-characteristic structure of aerospace thin-walled parts into rectangular thin plates. In accordance with Kirchhoff G.'s small deflection bending theory of elastic thin-plates and Daramberg's principle, the differential equations for the transverse vibration of the thin-walled parts are established, which aims to obtain the natural frequency as well as vibration mode function of the thin-walled parts. In consideration of damping characteristics and the external dynamic milling force after the magnetorheological fluid excitation solidification, this paper uses the mode superposition method and an improved dynamic response mathematical model of the magnetorheological damping fixture thin-walled parts system of the linear multiple degrees of freedom, which has different volumes of magnetorheological fluids under forced vibration, was established. The maximum error between the predicted and measured values of the fixtureworkpiece system dynamic response of displacement and acceleration is 16.2% and 15.5%, respectively. Finally, this paper verifies the feasibility as well as the effectiveness of the model through dynamics experiment and milling machining experiment.

Vibration coupling characteristics and grinding force control of an elastic component grinding system

“…Aiming at the chattering of the microscale thin-walled parts in high-speed micromilling, Jia et al (2021) established the milling force model, which provides a basis for selecting cutting parameters to achieve stable cutting. Jiang et al (2022) designed a mag-netorheological damping fixture to suppress the system vibration generated during the semi-active machining of thinwalled parts for aerospace. Liu et al (2023) established a coupling dynamic model of the grinding system and investigated the dynamic coupling effect between the elastic component and the grinding spindle.…”

Evaluation of Thin Wall Milling Ability Using Disc Cutters

“…Of the processes used in machining, those processes based on removing material from the workpiece by cutting have a special place. It can be seen that a large proportion of these processes are by cutting [ 1 , 2 , 3 , 4 , 5 , 6 , 7 ]. Essentially, machining is based on a strong compression of the workpiece material by the clearance surface of a cutting tool, until a shearing of the workpiece material occurs and material separates from the workpiece in the form of chips.…”