Upgraded stability analysis of milling operations by means of advanced modeling of tooling system bending

Totis, Giovanni; Albertelli, Paolo; Torta, Mattia; Sortino, Marco; Monno, Michele

doi:10.1016/j.ijmachtools.2016.11.005

Cited by 32 publications

(14 citation statements)

References 47 publications

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“…12), but many other harmonics are missing. During the simulation, a simplified model of the tool was assumed (all cutting edges are exactly the same), and some effects (appearing in the experiment) were ignored (for example, the effects of balancing and tool bending [44]). It should be emphasized that both the most important components of the vibration spectrum, as well as the general outline of the displacement and the evolution of vibrations obtained from RT simulations made on FPGA are consistent with the experimental results.…”

Section: F Experimental Results For the Real Milling Processmentioning

confidence: 99%

FPGA Based Real Time Simulations of the Face Milling Process

2020

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The article presents a successful implementation of the milling process simulation at the Field-Programmable Gate Array (FPGA). By using FPGA, very rigorous Real-Time (RT) simulation requirements can be met. The response time of the FPGA simulations is significantly reduced, and the time synchronization is better than in a typical RT system implemented in software. The FPGA-based approach is characterized by enormous flexibility when it comes to input and output operations that can be implemented deterministically in RT. Complex simulation software has been implemented using the High Level Synthesis technique, which is a relatively easy and fast approach for FPGA programming without using complex Hardware Description Languages. The hardware functions are based on procedures written in high-level C programming language. The mathematical descriptions of simulations, results of computer simulations, Hardware-in-the-Loop Simulation experiments, and real experiments are presented. The approach presented in this paper can be used to simulate the dynamics of various mechatronic systems.

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Section: F Experimental Results For the Real Milling Processmentioning

confidence: 99%

FPGA Based Real Time Simulations of the Face Milling Process

2020

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“…Milling was performed by the 11-edge Sandvik face milling cutter R390-125Q40-17H, /125 mm, cutting edge angle j = 90°. The use of tools with cutting edge angles j = 90 o does not require taking into account in the calculation model the phenomenon of tooling system bending, typical for relatively large cutter diameters [34].…”

Section: The Workpiecementioning

confidence: 99%

A technique of experiment aided virtual prototyping to obtain the best spindle speed during face milling of large-size structures

et al. 2020

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The paper presents an original method concerning vibration suppression problem during milling of large-size and geometrically complicated workpieces with the use of novel way of selecting the spindle speed. This consists in repetitive simulations of the cutting process for subsequent values of the spindle speed, until the best vibration state of the workpiece is reached. An appropriate method of obtaining a computational model, called a modal approach, consists in identifying the parameters of the workpiece model created using the Finite Element Method (FEM). Thanks to the results of the identification of the modal subsystem obtained by the Experimental Modal Analysis (EMA) method, it can be stated that the parameters obtained from the experiment and delivered from the computational model have been correctly determined and constitute reliable process data for the simulation tests. The Root Mean Square (RMS) values of time domain displacements are evaluated. The efficiency of the proposed approach is evidenced by chosen technique of mechatronic design, called Experiment Aided Virtual Prototyping (EAVP). The proposed method is verified on the basis of the results of the experimental research of the relevant milling process.

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“…In the light of these considerations, the following Shearing and Ploughing stationary cutting force model was adopted,

where

, and

[N/mm

] are the shearing coefficients in the tangential, radial, and axial directions, respectively, whereas

, and

[N/mm] are the plowing coefficients in the tangential, radial, and axial directions, respectively. This kind of model is a simplified version of well established cutting force models that can be found in literature [ 30 , 31 ]. Eventually, the components of the resultant force can be simply derived as follows,

…”

Section: Filter Performance Evaluationmentioning

confidence: 99%

Upgraded Kalman Filtering of Cutting Forces in Milling

Totis

Dombóvári

Sortino

2020

Sensors

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Advanced piezoelectric dynamometers with a wide frequency bandwidth are required for cutting force measurement in high-speed milling and micromilling applications. In many applications, the signal bandwidth is limited by the dynamic response of the mechanical system, thus compensation techniques are necessary. The most effective compensation techniques for a full 3D force correction require an accurate and complex identification phase. Extended Kalman filtering is a better alternative for input force estimation in the presence of unknown dynamic disturbances. The maximum bandwidth that can be currently achievable by Kalman filtering is approximately 2 kHz, due to crosstalk disturbances and complex dynamometer’s dynamics. In this work, a novel upgraded Kalman filter based on a more general model of dynamometer dynamics is conceived, by also taking into account the influence of the force application point. By so doing, it was possible to extend the frequency bandwidth of the device up to more than 5 kHz along the main directions and up to more than 3 kHz along the transverse directions, outperforming state-of-the-art methods based on Kalman filtering.

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Upgraded stability analysis of milling operations by means of advanced modeling of tooling system bending

Cited by 32 publications

References 47 publications

FPGA Based Real Time Simulations of the Face Milling Process

FPGA Based Real Time Simulations of the Face Milling Process

A technique of experiment aided virtual prototyping to obtain the best spindle speed during face milling of large-size structures

Upgraded Kalman Filtering of Cutting Forces in Milling

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