非均匀螺旋角铣刀的结构分析和稳定性预测
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摘要
高速铣削加工中,传统均匀螺旋角刀具不能有效抑制铣削过程中的再生颤振,但非均匀螺旋角铣刀却可以解决此类问题。本文通过分析各个铣削刃螺旋角和容屑角的空间结构关系,并结合"再生因子"探究其与再生颤振之间的关系。确定非均匀螺旋角与容屑角之间的控制方程,并建立铣削动力学模型。通过增强摄动同伦法(EMHPM)计算出非均匀螺旋角铣削加工过程中的稳定性叶瓣图。采用试验验证非均匀螺旋角刀具的有效性,利用本文方法与全变量插值法进行比较(对比试验1);利用均匀螺旋角刀具模型与非均匀螺旋角刀具模型进行比较(对比试验2)。试验结果表明,本文方法可以准确预测铣削稳定性,非均匀螺旋角可以有效提高铣削稳定性。
With tools Uniform helix angle can not effectively suppress the chatter of high-speed machining.The spatial structures of the helix angle and pitch angle of each flute are analyzed.And the chatter stability defined by "regeneration factor" is considered.Then the governing equation of the machining system for non-uniform helix angle with pitch angle and the milling dynamics model are established.Based on this model,the Enhanced Multistage Homotopy Perturbation Method(EMHPM) is used to compute the stability lobes.For verifying the feasibility of the stability prediction for the cutter with non-uniform helix angle,the proposed method in this paper is compared with the full variable interpolation method by contrast experiment 1 and by contrast experiment 2,the tool with non-uniform helix angle is compared with the tool of uniform helix angle.The results show that the proposed method is accurate to predict the stability and the tools with non-uniform helix angle indeed increase the stability in milling process.
With tools Uniform helix angle can not effectively suppress the chatter of high-speed machining.The spatial structures of the helix angle and pitch angle of each flute are analyzed.And the chatter stability defined by "regeneration factor" is considered.Then the governing equation of the machining system for non-uniform helix angle with pitch angle and the milling dynamics model are established.Based on this model,the Enhanced Multistage Homotopy Perturbation Method(EMHPM) is used to compute the stability lobes.For verifying the feasibility of the stability prediction for the cutter with non-uniform helix angle,the proposed method in this paper is compared with the full variable interpolation method by contrast experiment 1 and by contrast experiment 2,the tool with non-uniform helix angle is compared with the tool of uniform helix angle.The results show that the proposed method is accurate to predict the stability and the tools with non-uniform helix angle indeed increase the stability in milling process.
引文
[1]Suzuki N,Kojima T,Hino R,et al.A novel design method of irregular pitch cutters to attain simultaneous suppression of multi-mode regenerations[J].Procedia Cirp,2012,4:98-102.
[2]Altintas Y,Chan P K.In process detection and suppression of chatter in milling[J].International Journal of Machine Tools & Manufacture,1992,32(3):329-347.
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[8]Sivasakthivel P S,Murugan V V,Sudhakaran R.Cutting force prediction depending on process parameters by response surface methodology in milling[J].International Journal of Machining & Machinability of Materials,2012,11(2):137-153.
[9]Gilles P,Monies F,Rubio W.Modelling cutting forces in milling on torus cutters[J].International Journal of Machining & Machinability of Materials,2006,1(2):166-185.
[10]Aliyev R.A strategy for selection of the optimal machining sequence in high speed milling process.[J].International Journal of Computer Applications in Technology,2006,27(1):72-82.
[11]Chau-Chen Torng,Chikong Huang,Hsien-Ming Chang.Process control for aerospace chemical milling process[J].International Journal of Manufacturing Technology and Management,2009,18(3):308-318.
[12]Ammar A A,Jallouli M,Bouaziz Z.Design and development of a dynamometer for the simulation of the cutting forces in milling[J].International Journal of Automation & Control,2011,5(1):44-60.
[13]Ozkirimli O M,Budak E.Process simulation for five-axis machining for generalised milling tools[J].International Journal of Design Engineering,2010,3(3):232-246.
[14]Smaoui M,Bouaziz Z,Zghal A,et al.Compensation of a ball end tool trajectory in complex surface milling[J].International Journal of Machining & Machinability of Materials,2012,11(1):51-68.
[15]Guo Q,Sun Y,Jiang Y,et al.Prediction of stability limit for multi-regenerative chatter in high performance milling[J].International Journal of Dynamics & Control,2014,2(1):35-45.
[16]Olvera D,Elías-Zúňiga A,Martínez-Alfaro H,et al.Determination of the stability lobes in milling operations based on homotopy and simulated annealing techniques[J].Mechatronics,2014,24(3):177-185.
[17]Insperger T,Stépán G.Updated semi-discretization method for periodic delay-differential equations with discrete delay[J].International Journal for Numerical Methods in Engineering,2004,61(1):117-141.
[2]Altintas Y,Chan P K.In process detection and suppression of chatter in milling[J].International Journal of Machine Tools & Manufacture,1992,32(3):329-347.
[3]Altintas Y.Manufacturing automation[M].Cambridge:Cambridge University Press,2000.
[4]Turner S,Merdol D,Altintas Y,et al.Modelling of the stability of variable helix end mills[J].International Journal of Machine Tools & Manufacture,2007,47(9):1410-1416.
[5]Sims N D,Mann B,Huyanan S.Analytical prediction of chatter stability for variable pitch and variable helix milling tools[J].Journal of Sound & Vibration,2008,317(3-5):664-686.
[6]Takuya K,Suzuki N,Hino R,et al.A novel design method of variable helix cutters to attain robust regeneration suppression[J].Procedia Cirp,2013,8:363-367.
[7]Mehdi K.Modelling cutting force including thrust and tangential damping in peripheral milling process[J].International Journal of Machining & Machinability of Materials,2012,12(3):236-251.
[8]Sivasakthivel P S,Murugan V V,Sudhakaran R.Cutting force prediction depending on process parameters by response surface methodology in milling[J].International Journal of Machining & Machinability of Materials,2012,11(2):137-153.
[9]Gilles P,Monies F,Rubio W.Modelling cutting forces in milling on torus cutters[J].International Journal of Machining & Machinability of Materials,2006,1(2):166-185.
[10]Aliyev R.A strategy for selection of the optimal machining sequence in high speed milling process.[J].International Journal of Computer Applications in Technology,2006,27(1):72-82.
[11]Chau-Chen Torng,Chikong Huang,Hsien-Ming Chang.Process control for aerospace chemical milling process[J].International Journal of Manufacturing Technology and Management,2009,18(3):308-318.
[12]Ammar A A,Jallouli M,Bouaziz Z.Design and development of a dynamometer for the simulation of the cutting forces in milling[J].International Journal of Automation & Control,2011,5(1):44-60.
[13]Ozkirimli O M,Budak E.Process simulation for five-axis machining for generalised milling tools[J].International Journal of Design Engineering,2010,3(3):232-246.
[14]Smaoui M,Bouaziz Z,Zghal A,et al.Compensation of a ball end tool trajectory in complex surface milling[J].International Journal of Machining & Machinability of Materials,2012,11(1):51-68.
[15]Guo Q,Sun Y,Jiang Y,et al.Prediction of stability limit for multi-regenerative chatter in high performance milling[J].International Journal of Dynamics & Control,2014,2(1):35-45.
[16]Olvera D,Elías-Zúňiga A,Martínez-Alfaro H,et al.Determination of the stability lobes in milling operations based on homotopy and simulated annealing techniques[J].Mechatronics,2014,24(3):177-185.
[17]Insperger T,Stépán G.Updated semi-discretization method for periodic delay-differential equations with discrete delay[J].International Journal for Numerical Methods in Engineering,2004,61(1):117-141.