微铣削中考虑时变切削力系数的颤振稳定性预测
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摘要
颤振问题严重制约了微铣床的加工效率和加工质量。加工过程中刀具的磨损使得系统的颤振稳定性预测精度逐渐降低。为解决上述问题,引入时变可靠性理论,并用Gamma过程描述刀刃半径随切削时间的变化关系。建立了系统的时变切削力、时变稳定性和时变可靠性模型,分析了给定条件下系统的颤振稳定性和颤振可靠度随加工时间的变化关系。给出了微铣削在高速铣削过程中在给定切深和主轴转速下系统的颤振时变稳定性和颤振时变可靠性的算例研究。研究表明:随着加工时间的增加系统的颤振稳定性逐渐降低,该方法能够更准确的预测出不同加工时间内系统的颤振稳定性。
Chatter problems in milling severely affect productivity and quality of machining. Tool wear causes cutting force coefficient,process damping coefficient,and other parameters to change with cutting time. These variations significantly reduce the accuracy of chatter prediction using conventional methods. To solve this problem,the time-varying reliability theory was introduced,and Gamma process was used to describe the relationship between tool edge radius and cutting time. The models for a micro milling system's cutting force coefficients,time-varying stability and time-varying reliability were established. The changes of the system's chatter stability and chatter reliability with cutting time under the given conditions were analyzed. The system 's chatter time-varying stability and chatter time-varying reliability were investigated under given cutting depths and spindle speeds. The results of case study showed that with increase in cutting time,the system's chatter stability drops gradually; the proposed method can be used to predict the system's chatter stability more accurately within different cutting time intervals.
Chatter problems in milling severely affect productivity and quality of machining. Tool wear causes cutting force coefficient,process damping coefficient,and other parameters to change with cutting time. These variations significantly reduce the accuracy of chatter prediction using conventional methods. To solve this problem,the time-varying reliability theory was introduced,and Gamma process was used to describe the relationship between tool edge radius and cutting time. The models for a micro milling system's cutting force coefficients,time-varying stability and time-varying reliability were established. The changes of the system's chatter stability and chatter reliability with cutting time under the given conditions were analyzed. The system 's chatter time-varying stability and chatter time-varying reliability were investigated under given cutting depths and spindle speeds. The results of case study showed that with increase in cutting time,the system's chatter stability drops gradually; the proposed method can be used to predict the system's chatter stability more accurately within different cutting time intervals.
引文
[1]ALTINTA爦Y,BUDAK E.Analytical prediction of stability lobes in milling[J].Reliability Engineering&System Safety,1995,44(1):357-362.
[2]ALTINTA Y,BUDAK E.Analytical prediction of stability lobes in milling[J].CIRP Annals-Manufacturing Technology,1995,44(1):357-362.
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[10]LIU Yu.Mechanical systems and signal processing[J].Mechanical Systems and Signal Processing,2016,66/67(3):232-247.
[11]LI H Z,ZENG H,CHEN X Q.An experimental study of tool wear and cutting force variation in the end milling of Inconel718 with coated carbide inserts[J].Journal of Materials Processing Technology,2006,180(1/2/3):296-304.
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[13]BIERMANN D,BASCHIN A.Influence of cutting edge geometry and cutting edge radius on the stability of micromilling processes[J].Production Engineering,2009,3(4/5):375-380.
[14]AFAZOV S M,RATCHEV S M,SEGAL J.Modelling and simulation of micro-milling cutting forces[J].Journal of Materials Processing Technology,2010,210(15):2154-2162.
[15]AFAZOV S M,ZDEBSKI D,RATCHEV S M,et al.Effects of micro-milling conditions on the cutting forces and process stability[J].Journal of Materials Processing Technology,2013,213(5):671-684.
[16]JIN X,ALTINTAS Y.Chatter stability model of micro-milling with process damping[J].Journal of Manufacturing Science&Engineering,2013,135(3):1-9.
[17]李常有,张义民,王跃武.恒定加工条件及定期补偿下的刀具渐变可靠性灵敏度分析方法[J].机械工程学报,2012,48(12):162-168.LI Changyou,ZHANG Yimin,WANG Yuewu.Gradual reliability and its sensitivity analysis approach of cutting tool in invariant machining condition and periodical compensation[J].Journal of Mechanical Engineering,2012,48(12):162-168.
[18]NOORTWIJK J M V,WEIDE J A M V D,KALLEN M J,et al.Gamma processes and peaks-over-threshold distributions for time-dependent reliability[J].Reliability Engineering&System Safety,2007,92(12):1651-1658.
[19]MORIWAKI T,TOBITO M.A new approach to automatic detection of life of coated tool based on acoustic emission measurement[J].Journal of Engineering for Industry,1990,112(3):212-218.
[20]MALEKIAN M,PARK S S,JUN M B G.Modeling of dynamic micro-milling cutting forces[J].International Journal of Machine Tools&Manufacture,2009,49(7):586-598.
[21]THEPSONTHI T,ZELT T.3D Finite element process simulation of micro-end milling Ti-6Al-4V titanium alloy:experimental validations on chip flow and tool wear[J].Journal of Materials Processing Technology,2015,221:128-145.
[2]ALTINTA Y,BUDAK E.Analytical prediction of stability lobes in milling[J].CIRP Annals-Manufacturing Technology,1995,44(1):357-362.
[3]ELBEYLI O,SUN J Q,NAL G.A semi-discretization method for delayed stochastic systems[J].Communications in Nonlinear Science and Numerical Simulation,2005,10(1):85-94.
[4]DING Y,ZHU L,ZHANG X,et al.A full-discretization method for prediction of milling stability[J].International Journal of Machine Tools and Manufacture,2010,50(5):502-509.
[5]DUNCAN G,KURDI M,SCHMITZ T L,et al.Uncertainty propagation for selected analytical milling stability limit analyses[C]//34th North American Manufacturing Research Conference.[S.l.]:[s.n.],2006.
[6]ZHANG X,ZHU L,ZHANG D,et al.Numerical robust optimization of spindle speed for milling process with uncertainties[J].International Journal of Machine Tools and Manufacture,2010,61(1):9-19.
[7]PARK S S,RAHNAMA R.Robust chatter stability in micromilling operations[J].CIRP Annals-Manufacturing Technology,2010,59(1):391-394.
[8]SIMS N D,MANSON G,MANN B.Fuzzy stability analysis of regenerative chatter in milling[J].Journal of Sound and Vibration,2010,329(8):1025-1041.
[9]TOTIS G.RCPM—a new method for robust chatter prediction in milling[J].International Journal of Machine Tools and Manufacture,2009,49(3/4):273-284.
[10]LIU Yu.Mechanical systems and signal processing[J].Mechanical Systems and Signal Processing,2016,66/67(3):232-247.
[11]LI H Z,ZENG H,CHEN X Q.An experimental study of tool wear and cutting force variation in the end milling of Inconel718 with coated carbide inserts[J].Journal of Materials Processing Technology,2006,180(1/2/3):296-304.
[12]KARANDIKAR J M,ZAPATA R E,SCHMITZ T L.Combining tool wear and stability in high-speed machining performance prediction[D].Gainesville:University of Florida,2010:7-10.
[13]BIERMANN D,BASCHIN A.Influence of cutting edge geometry and cutting edge radius on the stability of micromilling processes[J].Production Engineering,2009,3(4/5):375-380.
[14]AFAZOV S M,RATCHEV S M,SEGAL J.Modelling and simulation of micro-milling cutting forces[J].Journal of Materials Processing Technology,2010,210(15):2154-2162.
[15]AFAZOV S M,ZDEBSKI D,RATCHEV S M,et al.Effects of micro-milling conditions on the cutting forces and process stability[J].Journal of Materials Processing Technology,2013,213(5):671-684.
[16]JIN X,ALTINTAS Y.Chatter stability model of micro-milling with process damping[J].Journal of Manufacturing Science&Engineering,2013,135(3):1-9.
[17]李常有,张义民,王跃武.恒定加工条件及定期补偿下的刀具渐变可靠性灵敏度分析方法[J].机械工程学报,2012,48(12):162-168.LI Changyou,ZHANG Yimin,WANG Yuewu.Gradual reliability and its sensitivity analysis approach of cutting tool in invariant machining condition and periodical compensation[J].Journal of Mechanical Engineering,2012,48(12):162-168.
[18]NOORTWIJK J M V,WEIDE J A M V D,KALLEN M J,et al.Gamma processes and peaks-over-threshold distributions for time-dependent reliability[J].Reliability Engineering&System Safety,2007,92(12):1651-1658.
[19]MORIWAKI T,TOBITO M.A new approach to automatic detection of life of coated tool based on acoustic emission measurement[J].Journal of Engineering for Industry,1990,112(3):212-218.
[20]MALEKIAN M,PARK S S,JUN M B G.Modeling of dynamic micro-milling cutting forces[J].International Journal of Machine Tools&Manufacture,2009,49(7):586-598.
[21]THEPSONTHI T,ZELT T.3D Finite element process simulation of micro-end milling Ti-6Al-4V titanium alloy:experimental validations on chip flow and tool wear[J].Journal of Materials Processing Technology,2015,221:128-145.