Analysis and Prediction of Surface Topographyin Peripheral Milling Based on Workpiece Vibration and Milling-Tool Structure

doi:10.12382/bgxb.2022.0289

Abstract

Abstract:

In the milling process, vibrations can lead to variations in the structure of machined parts, significantly influencing the machining quality of the finished surface. Therefore, investigating the milling formation method of the machined surface morphology is of great significance for predicting surface roughness and selecting reasonable machining parameters. First, by equivalently transforming the contact mode between workpiece and fixture into a linear spring damping system, the vibration differential equation of the workpiece is derived for the milling process by using the energy method. By using the coordinate transformation method, the modal analysis solution method is proposed for the vibration differential equations with constraint conditions to obtain the workpiece position deviation. Secondly, a method for determining the tool contact point and establishing the motion trajectory equation for the cutting edge in peripheral milling is presented. This enables the development of a discrete algorithm for surface topography by incorporating the workpiece position deviation. Experimental validations are conducted to verify the proposed algorithm for peripheral milling topography simulation. The results show that the maximum surface roughness error is 7.56% without considering the fixturing layout vibration, whereas the maximum contact force error is no more than 12% with fixturing layout vibration. Compared with calculations without clamping vibration considered, the calculation accuracy of contact force and surface roughness considering clamping vibration are improved by 3% and 4.72% (up milling)/3.00% (down milling), respectively.

Key words: milling, workpiece position deviation, milling vibration, surface topography

LIU Yang, QIN Guohua, WU Zhuxi, LOU Weida, LAI Xiaochun. Analysis and Prediction of Surface Topographyin Peripheral Milling Based on Workpiece Vibration and Milling-Tool Structure[J]. Acta Armamentarii, 2023, 44(7): 2132-2146.

Figures/Tables 18

Fig.1 Workpiece vibration model

Fig.2 Diagram of peripheral milling cutting edge movement

Fig.3 Diagram of surface formation in the coordinate plane Oxy

Fig.4 Peripheral milling experiment

Table 1 Peripheral milling parameters

刀具与工艺	参数	数值
	齿数z	2
刀具	半径R/mm	5
	螺旋角β/ (°)	45
	刃长L/mm	10
工艺	主轴转速ω/(r·min^-1)	500
	进给速度v_f/(mm·min^-1)	600

Fig.5 Surface morphology without considering vibration

Fig.6 Actual machined surface in stable machining(the left represents the actual machining table, the middle represents the black and white simulated surface, and the right represents the colored simulated surface)

Fig.7 Roughness measurement

Table 2 Experimental verification of surface morphology

铣削方式	实测粗糙度/μm	仿真粗糙度/μm	相对误差/%
逆铣	2.428	2.294	5.52
顺铣	3.057	2.826	7.56

Fig.8 3-2-1 fixturing layout

Table 3 Position and normal vector of locators

Fig.9 Workpiece position error without damping

Fig.10 Workpiece position error with damping

Fig.11 Experimental device

Fig.12 Supporting reaction force

Fig.13 Morphology of up milling

Fig.14 Morphology of down milling

Fig.15 Profile comparison

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