Abstract
During all the machining process, the milling cutter has to enter the workpiece either from the boundary or from the machined/unmachined surface, due to the change of machining sequence/cutter or the variation of cutting depth. Unlike the stable cutting process, the contact between cutter and machined workpiece changes significantly in the entering process, resulting in vibration and leaving marks on the machined surface. Aiming at in-depth understanding the mechanism of this phenomenon, this paper presents a novel time-domain simulation model to predict the dynamic response of the cutter during the entering process. Two typical entering conditions, including entering from the workpiece boundary and from the machined surface along the cycle path, are modeled based on the dynamic cutting force calculation by considering dynamic undeformed chip thickness created by consequential teeth engagement. Then, it is synthesized with the time-varying immersion angle and exit angle of cutter teeth in the entering process to simulate the dynamic cutting forces and cutter vibrations. To validate the developed model, eight conditions in boundary entering and six conditions in cycle path entering are carried out by comparing the collected data and the predicted results. Results show that the developed model could precisely predict the dynamic cutting forces and cutter vibration, especially the forces and displacements under the varied cutter-workpiece contact.
Highlights
As a long-developed traditional manufacturing process, machining is still significant in the contemporary manufacturing industry, including aerospace and aviation industry [1], for its high production quality, extensive application field, and high efficiency
A novel model for analyzing the flat-end cutter entering the workpiece process is developed, simulated, and validated with experiments. e developed model can be directly used for predicting cutting forces and the dynamic displacements of the cutter in the entering process where the cutting conditions keep changing
The simulation results of the entering process enable the process designers to analyze the dynamic response of the entering process in which way the action of dealing with possible vibration marks could be prepared
Summary
As a long-developed traditional manufacturing process, machining is still significant in the contemporary manufacturing industry, including aerospace and aviation industry [1], for its high production quality, extensive application field, and high efficiency. En, Insperger and Stepan [14] established a time-domain semidiscretization method via using Floquet theory, which is applicable in situations where analytical solutions do not exist On this foundation, research on improving calculation efficiency [15], solving multiaxis stability problem [16] and synthesizing ploughing effect into stability prediction [17], was carried out. A real-time updated machined surface that is formed by cutter motions was used in the modeling [25] Following this basic method of considering system vibration, the flexibility of workpiece has been modeled and synthesized into model [26], which is a significant progress in this area.
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