Abstract

Large thin-walled workpieces have large deformation and vibration during end milling due to their weak rigidity, which can lead to degradation of the surface quality of workpiece. To this end, this paper proposes a new method to suppress vibration and deformation during mirror milling of thin-walled workpieces by using a magnetic follow-up support fixture. The main idea is to design a fixture that can clamp around the milling area of the workpiece in real time, follow the tool motion and continuously provide a controlled air pressure force to the opposite side of the milling area without providing the mirroring support fixture that occupies a large space to the opposite side of workpiece. First, to accurately characterize the motion of the fixture, a mathematical model of the axial magnetic force considering the lateral offset is developed. On this basis, to efficiently investigate the capability of the fixture in improving the dynamic characteristics and dynamic response of workpiece, the finite element method (FEM) is used to analyze the frequency response functions (FRF) and the mode shapes of workpiece under the action of the fixture. Then, the vibration amplitude and deformation of workpiece on the milling path are simulated and studied by considering the variation of the air pressure and the position of the fixture. Finally, the prototype of the fixture is developed and then the effectiveness and feasibility of the proposed method are verified under the experimental tests with different machining parameters.

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