Chatter analysis and mitigation of milling of the pocket-shaped thin-walled workpieces with viscous fluid

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

doi:10.1016/j.ijmecsci.2020.106214

Cited by 31 publications

(7 citation statements)

References 56 publications

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“…The sound signal acquisition and FFT transformation are the main methods to determine the vibration. Dang et al [10] proposed a method to reduce machining chatter by liquid damping when thin-walled parts were machined and conducted a theoretical analysis of the method. Then, the vibration was also determined by a sound signal.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the profile of the blade considering machining vibration based on finite element analysis

Hou,

Wang,

2024

J. Phys.: Conf. Ser.

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Vibration is a problem that is easy to occur in the manufacturing process of thin-walled parts such as blades. Through the analysis of modal test results, the role of tool response and blade response in machining vibration is analyzed. With the aid of finite element simulation, the effects of damping ratio, cutting force peak, and force exciting position on the amplitude of response displacement are studied. The profile error caused by the machining vibration is simulated and the peak value of the response displacement amplitude is experimentally verified.

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Section: Introductionmentioning

confidence: 99%

Investigation of the profile of the blade considering machining vibration based on finite element analysis

Hou,

Wang,

2024

J. Phys.: Conf. Ser.

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“…The results showed that the damping of the system increased, and the milling force coefficients significantly decreased. The dynamic behavior of the milling process of a thin-walled workpiece immersed in a viscous fluid was also investigated by Dang et al 37 In this research, based on the principles of structure mechanics theory and fluid-structure dynamic interaction, the dynamic model of the spindle-tool system and the workpiece-viscous fluid system were developed and the dynamic parameters of the tool and workpiece such as natural frequency and mode shape were evaluated. The contact stiffness between the work piece and the fixture has not been addressed in this investigation.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the stability and contact stiffness of workpiece inside fixture in different machining conditions

Sohrabifard

Nategh

2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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The dynamic stability of machining processes is influenced by the dynamic stability of the workpiece and fixture assembly. This effect has not yet been sufficiently considered. Achieving dynamic stability by simply applying a large amount of clamping force is a basic method and involves damages such as elastic deformation of relatively thin workpieces, damage to the clamping surfaces, and high wear of fixture components resulting in malfunction. In spite of this, to the best knowledge of the present authors, the contact stiffness between workpiece and fixture as an influencing parameter has not been sufficiently paid attention by researchers and these parameters have not been taken into account in the equations of dynamic stability. The contact stiffness itself is influenced by the machining parameters. In the present study, the changes in contact stiffness in different machining conditions are investigated as a partial undertaking to fill the gap existing in the modeling of the machining dynamics. In this paper, by defining the mathematical model of the workpiece-fixture system and calculating the matrices of contact stiffness and fixture stiffness, the results of changes in various machining parameters in the stiffness of the workpiece-fixture system have been investigated. The results showed that high contact stiffness cannot be provided simply by applying the maximum force of the clamps. Rather, by increasing the spindle speed, the contact stiffness will increase significantly. Furthermore, by increasing the spindle speed, further increase in the contact stiffness will be achieved with lower feed rates, which will not be economically viable.

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“…Dang et al proposes a theoretical methodology to analyze the dynamic behavior of the thin-walled workpiece milling process filled with a viscous fluid to suppress chattering. Optimal process parameters have been achieved through a dynamic model of the spindle-tool system and a thin-walled workpiece immersed in a viscous fluid [34]. Zhang et al developed a novel technique to attenuate chattering vibration of a thin-walled workpiece by immersing the milling system in a viscous fluid.…”

Section: Introductionmentioning

confidence: 99%

Enhancing Chatter Stability for Milling Thin-Walled Blades by Designing Non-Uniform Allowance

Li,

Ding,

Tian

et al. 2023

Applied Sciences

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During the milling of thin-walled blades, the removal of material exhibits strong time-varying dynamics, leading to chatter and a decrease in surface quality. To address the issue of milling vibrations in the machining of complex thin-walled blades used in aerospace applications, this work proposes a process optimization approach involving non-uniform allowances. The objective is to enhance of he stiffness of the thin-walled parts during the milling process by establishing a non-uniform allowance distribution for the finishing process of thin-walled blades. By applying the theory of sensitive process stiffness and conducting finite element simulations, two processing strategies, namely uniform allowances and non-uniform allowances, are evaluated through cutting experiments. The experimental results demonstrate that the non-uniform allowance processing strategy leads to a more evenly distributed acceleration spectrum and a 50% reduction in amplitude. Moreover, the surface exhibits no discernible vibration pattern, resulting in a 35% decrease in roughness. The non-uniform allowance-processing strategy proves to be effective in significantly improving the rigidity of the thin-walled blade processing system, thereby enhancing the stability of the cutting process. These findings hold significant relevance in guiding the machining of typical complex thin-walled aerospace components.

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Chatter analysis and mitigation of milling of the pocket-shaped thin-walled workpieces with viscous fluid

Cited by 31 publications

References 56 publications

Investigation of the profile of the blade considering machining vibration based on finite element analysis

Investigation of the profile of the blade considering machining vibration based on finite element analysis

Investigation of the stability and contact stiffness of workpiece inside fixture in different machining conditions

Enhancing Chatter Stability for Milling Thin-Walled Blades by Designing Non-Uniform Allowance

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