Mechanism analysis and suppression for chatter and surface location error induced by error compensation

IF 3.9 2区工程技术 Q2 ENGINEERING, MANUFACTURING

Advances in Manufacturing Pub Date : 2025-03-10 DOI:10.1007/s40436-024-00537-6

Guan-Yan Ge, Yu-Kun Xiao, Jun Lv, Zheng-Chun Du

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引用次数: 0

Abstract

Error compensation is an economical and effective technique for achieving high machining accuracy. However, a new phenomenon has been detected in its application: error-compensation excited vibrations and further decreased surface quality in some cases. The mechanism of this phenomenon is important but remains unclear, and its main influencing factor remains an open question. To reveal this mechanism, a stability and surface quality analysis model of the dynamic milling process that considers the influence of error compensation is proposed for the first time. Error compensation can be considered as a quasi-static, periodic forcing term added to the milling system. The quasi-static part changes the cutting width, whereas the periodic forcing part mainly influences the instantaneous undeformed chip thickness, based on which the milling stability and surface location error are derived. Numerical simulations and milling experiments were conducted to validate the proposed model. The experimental results show that error compensation has little influence on milling stability but may decrease the surface quality when the compensation values between compensation cycles change significantly. The proposed method shows great potential for estimating and optimizing error compensation paths and improving the quality of machined surfaces.

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误差补偿引起的颤振和表面定位误差的机理分析与抑制

误差补偿是实现高加工精度的一种经济有效的技术。然而，在其应用中发现了一种新的现象：误差补偿激发振动，在某些情况下表面质量进一步下降。这一现象的机制很重要，但仍不清楚，其主要影响因素仍是一个悬而未决的问题。为了揭示这一机理，首次提出了考虑误差补偿影响的动态铣削过程稳定性和表面质量分析模型。误差补偿可以看作是在铣削系统中加入一个准静态的、周期性的强迫项。准静态部分改变切削宽度，周期强迫部分主要影响瞬时未变形切屑厚度，并以此为基础推导出铣削稳定性和表面定位误差。通过数值模拟和铣削实验验证了该模型的有效性。实验结果表明，误差补偿对铣削稳定性影响不大，但当补偿周期之间的补偿值变化较大时，可能会导致表面质量下降。该方法在估计和优化误差补偿路径以及提高加工表面质量方面具有很大的潜力。

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

Advances in Manufacturing Materials Science-Polymers and Plastics

CiteScore

9.10

自引率

3.80%

发文量

274

期刊介绍： As an innovative, fundamental and scientific journal, Advances in Manufacturing aims to describe the latest regional and global research results and forefront developments in advanced manufacturing field. As such, it serves as an international platform for academic exchange between experts, scholars and researchers in this field. All articles in Advances in Manufacturing are peer reviewed. Respected scholars from the fields of advanced manufacturing fields will be invited to write some comments. We also encourage and give priority to research papers that have made major breakthroughs or innovations in the fundamental theory. The targeted fields include: manufacturing automation, mechatronics and robotics, precision manufacturing and control, micro-nano-manufacturing, green manufacturing, design in manufacturing, metallic and nonmetallic materials in manufacturing, metallurgical process, etc. The forms of articles include (but not limited to): academic articles, research reports, and general reviews.