{"title":"Virtual Dynamics Model for 5-axis Machining of Thin-Walled Blades","authors":"B. Karimi, Y. Altintas","doi":"10.1115/1.4063286","DOIUrl":null,"url":null,"abstract":"\n The five-axis ball-end milling dynamics of thin-walled blades is presented. The cutting forces are predicted from the ball end mill–blade geometry engagement maps along the tool path. The Frequency Response Function (FRF) of the thin-walled blade is predicted using Finite Element shell elements, and it is updated along the toolpath as the metal is removed. The predicted cutting forces are applied on both the workpiece and tool FRFs to predict the forced vibrations and chatter stability at each tool location. A simplified method to update the cutter–workpiece engagement (CWE) is used to obtain the three-dimensional stability lobe diagram at each desired point on the blade. The integrated model is used to simulate the 5-axis machining of thin-walled blades in the digital environment. The proposed digital model is experimentally validated by machining a series of thin-walled rectangular plates and a twisted fan blade.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":null,"pages":null},"PeriodicalIF":2.4000,"publicationDate":"2023-08-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Manufacturing Science and Engineering-transactions of The Asme","FirstCategoryId":"5","ListUrlMain":"https://doi.org/10.1115/1.4063286","RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
引用次数: 0
Abstract
The five-axis ball-end milling dynamics of thin-walled blades is presented. The cutting forces are predicted from the ball end mill–blade geometry engagement maps along the tool path. The Frequency Response Function (FRF) of the thin-walled blade is predicted using Finite Element shell elements, and it is updated along the toolpath as the metal is removed. The predicted cutting forces are applied on both the workpiece and tool FRFs to predict the forced vibrations and chatter stability at each tool location. A simplified method to update the cutter–workpiece engagement (CWE) is used to obtain the three-dimensional stability lobe diagram at each desired point on the blade. The integrated model is used to simulate the 5-axis machining of thin-walled blades in the digital environment. The proposed digital model is experimentally validated by machining a series of thin-walled rectangular plates and a twisted fan blade.
期刊介绍:
Areas of interest including, but not limited to: Additive manufacturing; Advanced materials and processing; Assembly; Biomedical manufacturing; Bulk deformation processes (e.g., extrusion, forging, wire drawing, etc.); CAD/CAM/CAE; Computer-integrated manufacturing; Control and automation; Cyber-physical systems in manufacturing; Data science-enhanced manufacturing; Design for manufacturing; Electrical and electrochemical machining; Grinding and abrasive processes; Injection molding and other polymer fabrication processes; Inspection and quality control; Laser processes; Machine tool dynamics; Machining processes; Materials handling; Metrology; Micro- and nano-machining and processing; Modeling and simulation; Nontraditional manufacturing processes; Plant engineering and maintenance; Powder processing; Precision and ultra-precision machining; Process engineering; Process planning; Production systems optimization; Rapid prototyping and solid freeform fabrication; Robotics and flexible tooling; Sensing, monitoring, and diagnostics; Sheet and tube metal forming; Sustainable manufacturing; Tribology in manufacturing; Welding and joining