Abstract
In this work, we study how the mass and the lightweight connecting cable of an ultra-miniature accelerometer sensor (ACC) influence the frequency response function (FRF) of thin-wall aluminum workpieces, and its influence over the stability analysis of the milling process. To address these effects, experimental FRF measurements were performed by using a noncontact laser Doppler vibrometer (LDV) system to compare its collected data with those obtained by using the ACC. To correlate the discrepancies observed between measurements, we have used the structural modification method and finite element simulations to quantify the accelerometer mass and its connecting cable effects. Then, we computed the stability lobes diagram by using the enhanced, multistage homotopy perturbation method (EMHPM) to determine stable cutting parameters. It was found that the predicted stability lobes agree well with experimental data if the structural modification method is used to compensate the accelerometer measurements. This methodology could help researches and machinist with limited access to LDV equipment to perform reliable experimental dynamic measurements in cases where the cable and accelerometer mass could affect data accuracy.
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