Investigation on milling force of thin-walled workpiece considering dynamic characteristics of workpiece

Abstract

The idea of integral calculus is used in traditional milling force prediction methods. In the traditional method, the milling cutter is divided into many micro-elements, the force of each micro-element is calculated, and then the integral summation process is applied to all the micro-elements. In traditional milling force prediction methods, both the workpiece and the tool are assumed to be rigid bodies. In this paper, the method is improved; the Fourier series expansion is used to approximate the periodic milling force and the workpiece is considered as a single degree of freedom spring-damping-vibration system. Through the forced vibration model of periodic force, the vibration displacement of the workpiece is obtained. Then, the radial cutting depth is corrected by the vibration displacement of the workpiece. Finally, the original milling force is corrected with the corrected radial cutting depth. The milling force prediction model based on thin-walled workpiece is obtained through the above process. The model is named as variable-radial-cutting-depth-algorithm (VRCDA). Finally, the accuracy of this model was verified through modal test and milling force acquisition experiments.