Stability analysis in milling of the thin walled part considering multiple variables of manufacturing systems

Abstract

In order to improve the precision of the milling stability analysis, the more exact milling dynamic model considering multiple variables of manufacturing systems is proposed, and in order to reduce the calculation time for the stability analysis of the milling dynamic model, the fast calculation of the stability analysis is proposed. Firstly, the contact region of the milling cutter and the thin walled part is discretized into many small intervals, the milling dynamic model considering helix angle of the milling cutter, two degrees of freedom of the thin-walled part, and coupling dynamic characteristic of the tool–spindle system is established in a discrete small interval. The dynamic model in the small discrete interval considering multiple variables is transformed into equation of states, and the equation of states is integrated in the range of the milling depth to establish the milling dynamic model considering multiple variables of manufacturing systems. Secondly, in order to enhance the calculation speed of the stability analysis for the established dynamic model considering multiple variables, and to avoid the loss of information, the sampling rule of the delay term is defined based on the sampling rule of Shannon sampling theorem, and the delayed term is reconstructed in the discrete interval by using the Shannon interpolation function, and the validity of the fast calculation of the stability analysis is verified by two degrees of the freedom milling dynamic model. Finally, the validity of the established milling dynamic model considering multiple variables is verified by milling experiment, and the results show that the established dynamic model is effective.