On mechanism of tool-workpiece separation in multi-dimensional vibration-assisted milling

IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING
Bowen Song , Dawei Zhang , Xiubing Jing , Fujun Wang , Yun Chen , Huaizhong Li
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引用次数: 0

Abstract

As an innovative manufacturing technique, vibration-assisted milling (VAMILL) can enhance machining performance like improving cutting efficiency, surface quality, and tool life through controlling tool-workpiece separation. Available analyses on mechanism of VAMILL primarily focus on one-dimensional vibration assistance and often ignore the crucial influence of tool geometry on the cutting trajectories, leading to incomplete characterization of tool-workpiece separation conditions. This paper comprehensively investigates the mechanisms of tool-workpiece separation in multi-dimensional VAMILL through theoretical analysis and finite element simulation. A novel kinematic model is developed to identify the separation phenomena across one-, two-, and three-dimensional (1-D, 2-D, and 3-D) vibration configurations, incorporating the effects of tool geometry and rotation. Specific mathematical models are developed for distinct separation mechanisms, and quantitative formulas are derived to calculate separation time, re-engagement time, and separation time ratio across various trajectory patterns and vibration parameters. The calculation results are validated through finite element simulations, demonstrating excellent agreement with theoretical calculations with errors below 12 %. The findings provide quantitative criteria for initiating and controlling tool-workpiece separation in multi-dimensional VAMILL, enabling precise process parameter selection for optimal machining performance.
多维振动辅助铣削刀工分离机理研究
振动辅助铣削(VAMILL)作为一种创新的制造技术,可以通过控制刀-工件分离来提高切削效率、表面质量和刀具寿命等加工性能。现有的对VAMILL机理的分析主要集中在一维振动辅助上,往往忽略了刀具几何形状对切削轨迹的重要影响,导致对刀具-工件分离条件的描述不完整。本文通过理论分析和有限元仿真,全面研究了多维VAMILL中刀具-工件分离的机理。建立了一种新的运动学模型来识别一、二和三维(1-D、2-D和3-D)振动配置中的分离现象,并考虑了刀具几何形状和旋转的影响。针对不同的分离机制建立了特定的数学模型,并推导出定量公式来计算不同轨迹模式和振动参数下的分离时间、再接合时间和分离时间比。通过有限元仿真验证了计算结果,与理论计算结果吻合良好,误差在12%以下。研究结果为多维VAMILL中启动和控制刀具-工件分离提供了定量标准,实现了精确的工艺参数选择,以获得最佳的加工性能。
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
Journal of Manufacturing Processes
Journal of Manufacturing Processes ENGINEERING, MANUFACTURING-
CiteScore
10.20
自引率
11.30%
发文量
833
审稿时长
50 days
期刊介绍: The aim of the Journal of Manufacturing Processes (JMP) is to exchange current and future directions of manufacturing processes research, development and implementation, and to publish archival scholarly literature with a view to advancing state-of-the-art manufacturing processes and encouraging innovation for developing new and efficient processes. The journal will also publish from other research communities for rapid communication of innovative new concepts. Special-topic issues on emerging technologies and invited papers will also be published.
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