Machining stability enhancement in multi-axis milling of titanium hollow blade by introducing multiple damping and rigid supporters

Hou, Jun Ming; Zhao, Zhengcai; Fu, Yucan; Qian, Ning

doi:10.1016/j.jmapro.2021.01.016

Cited by 9 publications

(4 citation statements)

References 21 publications

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“…The cutter contact interval in Fig. 13 is taken into formula (22), and the theoretical predicted three-dimensional cutting force is converted to the dynamometer coordinate system, as shown in Fig. 14-(b).…”

Section: Simulation and Experimentsmentioning

confidence: 99%

“…In addition to the continuous changes in cutting geometry, the modal characteristics of the blades also have the characteristics of position differences [21], and the blade modal stiffness, modal mass and modal damping at each cutter location point are different. Hou [22] et al, introduced many damping supports and rigid supports in the hollow blade machining process, and proposed an optimization algorithm for the support position to improve the equivalent stability of the machining system. Liu [21] et al proposed a new blade clamping system, which improves the blade rigidity and effectively reduces cutting deformation and chatter.…”

Section: Cutter Contact Pointmentioning

confidence: 99%

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Cutting Dynamics Research on the Five-Axis Machining of Thin Curved Surface With Barrel-Taper-Ball Milling Cutter

Jiang¹,

Guo

Du³

et al. 2023

Preprint

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The use of blisk is essential for improving the performance of aviation engines, and the cutting of blade curved surface is the core of the blisk CNC machining. In response to the problem of traditional ball end milling cutter and barrel milling cutter that is difficult to take into account the quality and efficiency of curved blade machining, this article proposes a barrel-taper-ball milling cutter. The contour of the new cutter's barrel taper area is more fit with the blade curved surface, which is conducive to obtaining a larger cutting step and a tiny scallop height. Further, for the problem of weak-rigidity thin-wall curved surface machining chatter, the cutting dynamics model of the five-axis machining of the barrel-taper-ball milling cutter is established. Through the determination of the material contact criterion of the cutting edge micro element, the cutting geometry analysis algorithm of the five-axis processing of the blade curved surface is proposed. By deducing the forces in oblique cutting of the barrel taper area and the ball end area, the time-varying characteristics of the blade modes are explored, and the multiple frequently method theory is extended to the five-axis machining of the blade curved surface with barrel-taper-ball milling cutter. Finally, the stable state cutting parameter domain is constructed. Experiments and simulation indicate that the cutting step of the new cutter under the same surface roughness can increase by 7 times, the error of the cutting geometry solution of the blade curved surface is only 0.5%, the average error of the predicted three-dimensional cutting force is about 4.95%, and the optimized stable state cutting parameter can achieve machining without cutting chatter.

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Section: Simulation and Experimentsmentioning

confidence: 99%

Section: Cutter Contact Pointmentioning

confidence: 99%

Cutting Dynamics Research on the Five-Axis Machining of Thin Curved Surface With Barrel-Taper-Ball Milling Cutter

Jiang¹,

Guo

Du³

et al. 2023

Preprint

View full text Add to dashboard Cite

show abstract

“…Moreover, they calculated the best spindle speed range to avoid resonance during the polishing process, which provides a basis for reducing polishing vibration and improving blade polishing accuracy and efficiency. Hou et al [18] proposed an approach to enhance the machining stability of titanium hollow blades by introducing multiple damping and rigid supporters to the blade machining system in the multi-axis milling process, which effectively suppressed up to 40% noise signal and improved the processing stability. Although there are many pieces of research about the machining stability of thin-walled parts, the research on the vibration characteristics of the blade tip is still insufficient.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the effect of vibration characteristics on the grinding performance of aero-engine blade tip

Chen

Wu³

et al. 2022

Int J Adv Manuf Technol

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The machining quality of the blade tip has a great influence on the service performance and life of the aero-engine blade. The recent paper investigates the effect of vibration during the grinding process of the GH4169 nickel-based superalloy blade tip. Moreover, this paper proposes a theoretical model to link the unbalance of the grinding wheel, the vibration, and the surface topography characteristics of the blade. The results show that the blade vibration during grinding and the resulting non-linear change of the grinding depth could reduce the surface quality of the blade tip, and lead to differences in the surface quality of the blade tip in different areas, where the surface roughness in the entry area zone I is the largest, in the exit area zone III is the second largest, and the intermediate area zone III is the smallest. Grinding depth has a greater impact on the difference of the surface quality in the blade tip grinding process, especially when the grinding depth is greater than 4 μm, the difference of surface roughness increases significantly. On the other hand, the feed rate has little effect on the difference in surface quality. Adding damping block can reduce the surface roughness of the blade tip, however, it does not reduce the difference in surface quality.

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“…thin-walled parts [1][2]. The thin-walled parts are mostly machined by milling or electrolytic machining method.…”

mentioning

confidence: 99%

Investigation on the Influence of Electrolytic Milling Machining Parameters on the Machining Accuracy of Thin-walled Parts

Hou,

Wang,

et al. 2024

Preprint

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In order to reduce the weight of aircraft parts, they are often designed as thin-walled structures and the thin-walled structure will deform when the cutting force is generated and applied to the thin-walled parts for its poor rigidity. So the machining accuracy of thin-walled parts will be reduced for the deformation in milling process. Then, the electrolytic milling method composed of milling and electrochemical machining is proposed to reduce workpiece deformation and improve machining accuracy of thin-walled parts. The machining parameters of milling method and electrochemical machining method, which connected with the material removal thickness and machining accuracy, are analysed. The machining parameters, which contain spindle speed, feed rate, voltage, electrolyte concentration, are selected and the machining accuracy measuring experiments are implemented. And the machining accuracy predicting model of thin-walled parts is established on the basis of electrolytic milling experimental results. The effects of milling parameters and electrochemical machining parameters on material removal thickness are studied separately. In addition, the accuracy predicting model is also validated by electrolytic milling experiments. The results show that the machining accuracy of electrochemical milling is superior to that of milling. It is a composite machining method that combines the advantages of electrochemical machining and milling.

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Machining stability enhancement in multi-axis milling of titanium hollow blade by introducing multiple damping and rigid supporters

Cited by 9 publications

References 21 publications

Cutting Dynamics Research on the Five-Axis Machining of Thin Curved Surface With Barrel-Taper-Ball Milling Cutter

Cutting Dynamics Research on the Five-Axis Machining of Thin Curved Surface With Barrel-Taper-Ball Milling Cutter

Investigation of the effect of vibration characteristics on the grinding performance of aero-engine blade tip

Investigation on the Influence of Electrolytic Milling Machining Parameters on the Machining Accuracy of Thin-walled Parts

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