Tool Point Frequency Response Prediction for High-Speed Machining by RCSA

Schmitz, Tony L.; Davies, Matthew A.; Kennedy, Michael D.

doi:10.1115/1.1392994

Cited by 179 publications

(83 citation statements)

References 20 publications

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“…(2) Experimentalanalytical method. Schmitz et al [17,18] proposed the receptance coupling substructure analysis (RCSA) method. By using this method, the interface parameters of cutterholder-spindle can be determined and the FRFs can be analytically calculated.…”

Section: Milling Dynamics Modelmentioning

confidence: 99%

On time-domain methods for milling stability analysis

Ding

Zhu

2012

Chin. Sci. Bull.

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As a basic and advanced machining technique, the high-speed milling process plays an important role in realizing the goal of high performance manufacturing. From the viewpoint of machining dynamics, obtaining chatter-free machining parameters is a prerequisite to guaranteeing machining accuracy and improving machining efficiency. This paper gives an overview on recent progress in time domain semi-analytical methods for chatter stability analysis of milling processes. The state of art methods of milling stability prediction in milling processes and their applications are introduced in detail. The bottlenecks involved are analyzed, and potential solutions are discussed. Finally, a brief prospect on future works is presented. High speed milling is widely utilized in manufacturing of complex surfaces for the fields of aerospace, ship, automotive, dies and molds etc., due to its advantage of obtaining high machining accuracy and high material removal rate with keeping low-amplitude cutting forces. Regarding to modeling of machining processes, the research topics on high speed milling can be categorized as: tool path planning, machining dynamics and machining physical modeling. Tool path planning is to plan the tool path according to the workpiece model, machining strategy and required machined error [1][2][3][4][5]. From the viewpoint of machining dynamics, the relative vibration between the workpiece and cutter in the milling process is the main reason of reducing product surface quality and limiting the production efficiency. To suppress the vibration impact by optimizing the machining parameters, the following two questions need to be addressed.(1) Stability analysis based on the dynamics of milling processes. As far as chatter vibrations are concerned, there are four different mechanisms: regeneration [6], mode coupling [7], friction [8] and thermo-mechanics of chip formation [9]. In milling processes, regenerative chatter is the most common form of self-excited vibration to reduce surface quality and machining efficiency [10,11]. The works on analysis of the stability of milling processes focus on calculating the stability boundary of the machining parameters based on the dynamic models characterizing the milling processes.(2) Machining accuracy analysis on the basis of stability analysis. Due to forced vibrations in milling processes, chatter-free machining parameters cannot ensure high performance machining. Vibration-induced surface errors can be classified as surface location error (SLE) [12] and surface roughness [13]. It is essential to take the stability and dynamical errors into account in machining optimization models to achieve high performance milling.

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Section: Milling Dynamics Modelmentioning

confidence: 99%

On time-domain methods for milling stability analysis

Ding

Zhu

2012

Chin. Sci. Bull.

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“…The receptance coupling method enables two substructures to be joined as shown in Figure 2, where f 1 , f 2 [12]. The receptance coupling method is employed to correlate experimental and analytical data rather than the component mode synthesis (CMS) approach, because CMS requires accurate mode shapes that are often difficult to obtain from experimental measurements.…”

Section: Receptance Couplingmentioning

confidence: 99%

“…Then, the curve-fitting algorithm is employed to identify the modal parameters of the joints that can be stored in a database for coupling of arbitrary dynamics in the FE analysis. (12) To demonstrate the feasibility of the joint identification algorithm, EMA is performed to acquire the FRF by impacting the structure and measuring the vibration responses. In addition, FE analysis was performed to acquire the information on arbitrary Substructure A.…”

Section: Finding the Rdof Responses At Substructure Bmentioning

confidence: 99%

Substructure Coupling With Joint Idenfication for Reconfigurable Manufacturing Systems

Chae¹,

Park

Lin³

2011

PCEEA

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“…System B was modeled as a single DOF substructure with free-free boundary conditions; it consisted of a mass, m 2 , connected to a massless coordinate, x 3 , through a spring, k 2 , and a viscous damper, c 2 . The response of the assembly, system C, at coordinate X 2 (representing the uppermost point on the top flexure) for a harmonic force, F 2 (applied at coordinate X 2 ) is computed using receptance coupling substructure analysis (RCSA) [5][6][7] based upon the receptances of the two single DOF substructures. It is assumed that the substructure receptances for the rotational degrees-of-freedom are negligible (by design for flexures) and that the substructures are rigidly connected.…”

Section: Model Developmentmentioning

confidence: 99%