Comprehensive effect of multi-parameters on vibration in high-speed precision milling

Abstract

Precision milling processes have been widely applied to manufacturing parts in fields including automotive, aerospace, and precision machinery. Vibrations created in the milling process contribute significantly to machining accuracy and quality. While the direct and interaction effects of machining parameters on vibration amplitude have been analyzed statistically, the comprehensive effect considering machine tool non-cutting vibrations has not been fully explored. In this paper, the comprehensive effect of several machining parameters on the process vibration is studied and a cutting vibration signal-based optimization method is proposed. First, taking the frequency response function (FRF) and non-cutting rotating vibration into consideration, the spindle speed–related dynamic load in machining is studied to analyze the influence of machining accuracy. The main factors influencing the process dynamic performance are then studied using orthogonal experimental analysis of the vibration signal in milling. Finally, the comprehensive effect is determined and the optimal selection approach of machining parameters is put forward based on the experimental research of vibration in machining processes.