Abstract
The paper presents an innovative method of solving the problem of vibration suppression during milling of large-size details. It consists in searching for the best conditions for clamping the workpiece based on a rapid modal identification of the dominant natural frequencies only and requires repetitive changes in the tightening torque of the clamping screws. Then, by estimating the minimum work of the cutting forces acting in the direction of the width of the cutting layer, it is possible to predict the best fixing of the workpiece. Application of the method does not require the creation and identification of a computational model of the process or preliminary numerical simulations. The effectiveness of this method was confirmed by the evaluation of the Root Mean Square (RMS) of the vibration level in the time domain observed during the actual face milling process. The worst results were obtained for the configuration of supports tightened with a torque of 90–110 Nm, and the best—with a torque of 50 Nm.
Highlights
The paper presents an innovative method of solving the problem of vibration suppression during milling of large-size details
Full face milling of surface 1 was first performed by the tool starting from the vicinity of accelerometer 22 to accelerometer 25
An innovative method of solving the problem of vibration suppression during milling of large-size details by predicting the best conditions for clamping the workpiece on the milling machine table is developed in the paper
Summary
The paper presents an innovative method of solving the problem of vibration suppression during milling of large-size details. The demand for the production of large parts is generally increasing, while the current scientific research results lag behind and are usually far from the expected requirements in this field[9] Numerous methods make it possible to search for the optimal level of vibrations by considering mainly the phenomena observed in the direction of the thickness of the cutting layer[2,3,4,7,10,11]. The subject of the paper is a method of searching for the conditions for minimizing the vibration level of a tool-large size flexible workpiece, with the same technological parameters of the milling process, but with different workpiece clamping conditions, resulting in different stiffness It is a special case of the formulation of a problem specific to semi-active systems, the control signals are not explicitly present here. Stiffness changes for the two degrees of freedom of a rather smaller milling system are performed by piezoelectric stack actuators acting on a rotating tool[19]
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