Simulation of Oscillation Frequency Effects on Complex Shape Part Milling

Abstract

The study shows that auto-oscillations occur even at low-speed turning. The paper includes a literature review revealing the reasons for machining vibrations. It is difficult to analytically describe the physical processes in the cutting area, so we used simulation. Moreover, milling is the most difficult process to describe and research. The variable magnitudes/directions of the cutting forces resulting in extra auto-oscillations make the analysis even more complex. It is shown that reducing the cutting speed leads to lower vibrations, and to lower output, higher rigidity, and damping capacity. It is important to know the natural frequency of the workpiece to choose the right cutting mode. The finite element method and SoldWorks CAD models were used for simulating the complex shape part dynamic behavior. We found out that the workpiece natural frequency is 6.5 times higher than the forced oscillation frequency.