Dynamics modelling and Layout optimization of CFRP in-situ machining system

Abstract

The multi-support reconfigurable compliant tooling and robotic in-situ processing method provide a new technical direction for CFRP milling edge processing. Aiming at the layout optimization of CFRP in-situ machining system (CFRPIMS), the dynamics characteristics of the whole system were studied. A rigid-flexible coupling dynamics model of the CFRPIMS was proposed by applying transfer matrix method for multibody systems (MSTMM), treating CFRP as a thin-walled flexible plate and supporting fixtures as rigid bodies. And then the natural frequency and dynamics responses under the different support layout are simulated, which are verified by modal tests and excitation tests. To improve the support rigidity of CFRP workpieces, the optimization model of overall layout of the compliant tooling was established combined with genetic algorithm. Based on the milling test results, compared with the original scheme, the optimization method can effectively reduce the vibration response of the workpiece in the y-direction (along the milling edge direction) and the z-direction (perpendicular to milling edge direction) by more than 60%.