Thin-Walled Part Machining Process Parameters Optimization based on Finite-Element Modeling of Workpiece Vibrations

Bolsunovskiy, Sergey; Vermel, Vladimir Dmitrievich; Gubanov, G.; Kacharava, I.; Kudryashov, A.

doi:10.1016/j.procir.2013.06.102

Cited by 40 publications

(12 citation statements)

References 6 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Therefore, optimization strategies are generally based on the selection of spindle speed [23], which governs the frequency content of the cutting forces and thus could reduce vibration levels, without affecting productivity or altering system layout. However, the selection of spindle speed has conflicting requirements for forced and chatter vibrations.…”

Section: Optimization Strategymentioning

confidence: 99%

Process Parameters Optimization of Thin-Wall Machining for Wire Arc Additive Manufactured Parts

et al. 2020

View full text Add to dashboard Cite

Additive manufacturing (AM) is an arising production process due to the possibility to produce monolithic components with complex shapes with one single process and without the need for special tooling. AM-produced parts still often require a machining phase, since their surface finish is not compliant with the strict requirements of the most advanced markets, such as aerospace, energy, and defense. Since reduced weight is a key requirement for these parts, they feature thin walls and webs, usually characterized by low stiffness, requiring the usage of low productivity machining parameters. The idea of this paper is to set up an approach which is able to predict the dynamics of a thin-walled part produced using AM. The knowledge of the workpiece dynamics evolution throughout the machining process can be used to carry out cutting parameter optimization with different objectives (e.g., chatter avoidance, force vibrations reduction). The developed approach exploits finite element (FE) analysis to predict the workpiece dynamics during the machining process, updating its changing geometry. The developed solution can automatically optimize the toolpath for the machining operation, generated by any Computer Aided Manufacturing (CAM) software updating spindle speed in accordance with the selected optimization strategies. The developed approach was tested using as a test case an airfoil.

show abstract

Section: Optimization Strategymentioning

confidence: 99%

Process Parameters Optimization of Thin-Wall Machining for Wire Arc Additive Manufactured Parts

et al. 2020

View full text Add to dashboard Cite

show abstract

“…The variation of the spindle speed can induce chatter, but the feed rate variation can hardly do that. Because the variation of the spindle speed is the variation of excitation frequency, the chatter will occur if the frequency is matched with a natural frequency of the workpiece, cutter or even machine tool [47]. However, the feed rate variation affects the value of the cutting force, which hardly conducts dynamic instability for a stable process.…”

Section: Vibration Response Analysismentioning

confidence: 99%

Feed Rate Variation Strategy for Semi-Conical Shell Workpiece in Ball Head End Milling Process

2020

View full text Add to dashboard Cite

The semi-conical shell workpiece is a special kind of thin-wall part that is commonly used in aerospace and mold industries. Due to the special stiffness distribution and weak rigidity for the area with a large radius, the machining quality of the semi-conical shell is sensitive to both cutting force and vibration. Conventionally, constant conservative machining parameters are chosen to ensure the workpiece deformation and surface quality, which will reduce the machining efficiency. Based on the cutting force and vibration response simulation of the whole milling process. A feed rate variation strategy is proposed for the ball head end milling process of the semi-conical shell workpiece. The cutting force, dynamic performance and stability prediction are obtained considering the shape and boundary conditions of the workpiece and the contour tool path of the milling process. Variable feed rate is used in the milling simulation to find the harmony between machining quality and efficiency. User-defined vibration amplitude and another user-defined cutting force threshold are used to find the optimal feed rate for each simulation segment. Both continuous and discrete feed rate variation strategies are proposed, and the improved discrete feed rate variation is applied in the milling experiment. About 25% of the consumed time is saved with almost the same machining quality by the experimental results.

show abstract

“…Chatter prediction starts by calculating the FRF of the workpiece and tool-spindle using impact hammer test [15,26,30,31,36,37,38]. One point of the tool and different locations of the workpiece are hit, and excitation responses are recorded by accelerometers.…”

Section: Computational Solutionsmentioning

confidence: 99%

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

et al. 2019

View full text Add to dashboard Cite

Thin-wall parts are common in the aeronautical sector. However, their machining presents serious challenges such as vibrations and part deflections. To deal with these challenges, different approaches have been followed in recent years. This work presents the state of the art of thin-wall light-alloy machining, analyzing the problems related to each type of thin-wall parts, exposing the causes of both instability and deformation through analytical models, summarizing the computational techniques used, and presenting the solutions proposed by different authors from an industrial point of view. Finally, some further research lines are proposed.

show abstract

Thin-Walled Part Machining Process Parameters Optimization based on Finite-Element Modeling of Workpiece Vibrations

Cited by 40 publications

References 6 publications

Process Parameters Optimization of Thin-Wall Machining for Wire Arc Additive Manufactured Parts

Process Parameters Optimization of Thin-Wall Machining for Wire Arc Additive Manufactured Parts

Feed Rate Variation Strategy for Semi-Conical Shell Workpiece in Ball Head End Milling Process

Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches

Contact Info

Product

Resources

About