Abstract
The full-discretization method introduced by Ding has high computational efficiency without loss of any numerical precision regardless of low and high radial depth of cut for the stability analysis of ordinary milling operation in time domain. Contrast to ordinary milling, it exists the separation phenomenon between each cutter tooth and the workpiece in feed ultrasonic milling operation. So before analyzing the system stability by the full-discretization method, the contact state between the cutter tooth and the workpiece should be made clear. In this paper, the trajectory method is proposed by the authors to judge the contact state between the cutter tooth and the workpiece. The stability analysis is developed for separated feed ultrasonic and ordinary end milling operations by the above methods and is validated via time domain simulations and experiments for both operations. The analyses show excellent agreement with both the time domain simulations and the experiments. Further, several end milling experiments were conducted that demonstrate the result ultrasonic vibration in feed direction can suppress chatter in machining operations.
Highlights
IntroductionHigh speed milling technology with high production efficiency, high machining accuracy, high machining surface quality and low cost advantages, has gradually become the mainstream of machining technology, widely used in aviation, aerospace, mold, automotive and other fields [1]
High speed milling technology with high production efficiency, high machining accuracy, high machining surface quality and low cost advantages, has gradually become the mainstream of machining technology, widely used in aviation, aerospace, mold, automotive and other fields [1].in traditional machining technology the cutting vibration displacements between the last time and this time have produced phase difference, resulting in the occurrence of machining chatter
Trajectory method has been put forward based on motion characteristics of feed ultrasonic milling
Summary
High speed milling technology with high production efficiency, high machining accuracy, high machining surface quality and low cost advantages, has gradually become the mainstream of machining technology, widely used in aviation, aerospace, mold, automotive and other fields [1]. Ding Ye and co-workers introduced a new time domain method called full-discretization that is based on the direct integration scheme for prediction of milling stability [10,11,12,13] This method has high computational efficiency without loss of any numerical precision regardless of low and high radial depth of cut. This paper has proposed trajectory method to judge cutting separation or not, found out the real instantaneous chip thickness, established time delay differential equations of feed ultrasonic milling system, used the full-discretization method to study this system stability, realized numerical simulation by MATLAB7.1 software, obtained this system stability lobe diagrams, and compared with ordinary milling
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