Methodic of Rational Cutting Conditions Determination for 3-D Shaped Detail Milling Based on the Process Numerical Simulation

Abstract

The paper is devoted for the analysis of the dynamics effect on the 5-axis milling process of flexible details. The integrated model of milling dynamics composed by block principle in the paper is presented. The model consist of: 1) dynamical model of tool; 2) dynamical model of machined detail based on Finite Element Method (FEM); 3) phenomenological model of cutting forces and 4) algorithm of geometry modeling for instant machined chip thickness calculation. Regeneration mechanism of cutting and calculation of the machined surface are into this algorithm embedded. The elaborated model is adapted for 5-axis processing of the profiled details with 3-D complex geometry. Alteration of workpiece dynamic characteristics while the allowance removal is considered by the special algorithm of FEM grid changing based on the results of cutting geometry modeling. The results of modeling give us opportunity determine cutting forces, estimate the machined surface quality, calculate the magnitude and the character of tool and detail vibrations under the specified cutting conditions. The conception of increasing the process quality and the machinability for 3-D shaped details machining is offered in the paper. Applying the specified efficient conditions the undesired dynamical effects can be excluded on the base of the results of multi-variant simulation for milling dynamics varying the technological parameters at the different region of the processing route.

Ensuring the chatter stability of milling by optimizing the workpiece stock

“…This section considers an example of optimizing the law of the change of stock for finish workpiece milling based on the results of modeling dynamic of up milling of a flexible plate by a rigid instrument in the 3DCUT software [18]. FEM model of the workpiece, tool trajectory and its cutting edges in the initial moment of time and feed directions are shown in Fig.…”

Investigation of the plain milling process dynamic stability taking into account the contact interaction on the flank face of the cutting wedge

“…It is needed to carry out research into the technological operation dynamics to define the favorable machining modes, which are free from high-amplitudes vibrations in the system "tool-workpiece" [6,7]. There are plenty of approaches how to take into account the process damping in the literary sources.…”

Chatter suppression in boring with tool position feedback control

“…This energy supply will excite chatter. As chatter vibrations are inherent but unwanted for metal cutting many researches are aiming to analyze methods of chatter suppression [3][4][5][6][7][8][9][10][11][12][13][14][15] and chatter prediction [16][17][18][19][20][21][22][23].…”

“…Nevertheless, the advantage of this method lies in fact that a lot of important nonlinear effects can be taken into consideration. A possible tool exit from material in case vibration magnitudes are too high [16], a nonlinear cutting forces dependence on a cut-off thickness [17], energy dissipation on a tool flank face [18], complicated 3D geometry of a tool and of a workpiece [19,20], variable dynamic properties of a workpiece [19] are examples of these nonlinear effects.…”