A novel approach of stability and topography prediction in five-axis ball-end milling process through workpiece-edge-coupling

IF 1.9 3区 工程技术 Q3 ENGINEERING, MANUFACTURING
Shuiyuan Wu, Dongju Chen, Ri Pan, Jinwei Fan, Yuhang Tang
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引用次数: 0

Abstract

By studying the workpiece-edge-coupling (WEC) in five-axis ball-end milling, the contact characteristics between the workpiece and edge curve are analyzed, and the chip model is extracted and simplified. The edge curve involved in the cutting process of each edge are calculated at each time and a new instantaneous numerical chip thickness model is established. Then the milling forces and stability lobe diagram (SLD) are calculated in following cut process with lead and tilt angle. The milling forces and SLD of lead angle at 15° and tilt angle at −15° are verified by comparing with Otzurk model as references, and it is found the SLD of WEC model can reflect the unstable points more properly than that of Otzurk model. Also the vibration in [Formula: see text] and [Formula: see text] directions show a divergence trend, which proves the high precision for the new algorithm adapted to the stability prediction of five-axis ball-end milling process. In addition, the surface topography is acquired considering lead and tilt angle as well as forced vibration, and the result is consistent with the experiment in the existing literature. It is found that the milling forces, SLD and surface topography show the same variation trend with the increase of lead and tilt angle. Besides, the stability region significantly expands and the surface topography improves by applying positive tilt angle other than the negative. Then, under the conditions of positive lead and tilt angle, increasing lead angle and decreasing tilt angle reduces the milling force, expands the stability region of SLD and improve the surface topography. The optimized tool posture is acquired by the coincident analysis of milling force, SLD and surface topography under different lead and tilt angle.
通过工件边缘耦合实现五轴球端铣削过程稳定性和形貌预测的新方法
通过研究五轴球头铣削中的工件-边缘耦合(WEC),分析了工件与边缘曲线的接触特性,提取并简化了切屑模型。计算了每个刃口切削过程中每次涉及的刃口曲线,建立了新的瞬时切屑厚度数值模型。然后,计算了后续切削过程中的铣削力和稳定叶图(SLD)。通过与 Otzurk 模型对比,验证了导程角为 15°、倾斜角为-15°时的铣削力和 SLD,发现 WEC 模型的 SLD 比 Otzurk 模型更能正确反映不稳定点。同时,[公式:见正文]和[公式:见正文]方向的振动呈现发散趋势,这证明新算法适用于五轴球头铣削过程的稳定性预测具有很高的精度。此外,考虑到前倾角和倾斜角以及强迫振动,还获取了表面形貌,结果与现有文献中的实验结果一致。结果发现,随着导程和倾斜角的增加,铣削力、SLD 和表面形貌呈现出相同的变化趋势。此外,正倾角比负倾角的稳定性区域明显扩大,表面形貌也有所改善。因此,在正前角和倾斜角条件下,增大前角和减小倾斜角可以减小铣削力,扩大 SLD 的稳定区域,改善表面形貌。通过对不同导程角和倾斜角下的铣削力、SLD 和表面形貌的重合分析,获得了优化的刀具姿态。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
CiteScore
5.10
自引率
30.80%
发文量
167
审稿时长
5.1 months
期刊介绍: Manufacturing industries throughout the world are changing very rapidly. New concepts and methods are being developed and exploited to enable efficient and effective manufacturing. Existing manufacturing processes are being improved to meet the requirements of lean and agile manufacturing. The aim of the Journal of Engineering Manufacture is to provide a focus for these developments in engineering manufacture by publishing original papers and review papers covering technological and scientific research, developments and management implementation in manufacturing. This journal is also peer reviewed. Contributions are welcomed in the broad areas of manufacturing processes, manufacturing technology and factory automation, digital manufacturing, design and manufacturing systems including management relevant to engineering manufacture. Of particular interest at the present time would be papers concerned with digital manufacturing, metrology enabled manufacturing, smart factory, additive manufacturing and composites as well as specialist manufacturing fields like nanotechnology, sustainable & clean manufacturing and bio-manufacturing. Articles may be Research Papers, Reviews, Technical Notes, or Short Communications.
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