Abstract
The free vibration behavior and stability of composite milling bar with large aspect ratio are analyzed. Specifically, the free vibration equations are derived based on Euler Bernoulli beam theory and Hamilton’s principle and solved by Galerkin method. In addition, to investigate the stability of the cutting system with a rotating composite milling bar, this study develops an analytical model for regeneration and cutting force fluttering, in which the internal damping, external damping, gyroscopic effect, and inertial effect are considered. The subsequent stability lobes are obtained by the time domain method. Then, the stability of composite and conventional metal milling bar is compared. The effects of internal damping, external viscous damping, ply angle, gyroscopic effect, and inertial effect on cutting stability are analyzed.
Highlights
Milling is one of the most extensively used machining methods, where the milling bar for deep groove milling is usually designed as a long and slender cantilever structure
Kim et al [27] studied the response and stability of a high-speed rotating composite shaft subjected to the typical cutting forces of milling, and Timoshenko beam theory was used for the structural dynamic model of rotating composite shaft
This paper aims at providing a new dynamic model of composite milling bar, which is a cylindrical tubular composite shaft modeled as a continuous distributed Euler Bernoulli beam without considering the thickness of the bar
Summary
Milling is one of the most extensively used machining methods, where the milling bar for deep groove milling is usually designed as a long and slender cantilever structure. The composite material offers the possibility to simultaneously enhance the dynamic stiffness and fundamental natural frequency of milling bars with large aspect ratio. Altintas et al [10,11,12] obtained the stability lobe diagram of a milling system in frequency domain by the frequency analysis method This method has a high computational efficiency, and the gyroscopic effects activated by the rotation of milling bar is included in the analysis. Kim et al [27] studied the response and stability of a high-speed rotating composite shaft subjected to the typical cutting forces of milling, and Timoshenko beam theory was used for the structural dynamic model of rotating composite shaft. A deflection-dependent cutting forces model with regeneration delay effects was established and the dynamic milling model was solved by frequency domains method. Negative damping effect, which is not conductive to the cutting stability
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