ACTA AERONAUTICAET ASTRONAUTICA SINICA >
Prediction and experimental verification of time-varying dynamic parameters for milling thin-walled workpieces
Received date: 2024-11-15
Revised date: 2024-12-03
Accepted date: 2025-03-16
Online published: 2025-03-31
Supported by
National Natural Science Foundation of China(51765047);Key Projects of Jiangxi Provincial Natural Science Foundation(20232ACB204019);Guangxi Science and Technology Major Program(Guike AA23023027-3)
The time-varying characteristics of dynamic parameters during the thin-walled part milling process significantly affect the prediction of milling stability regions. To accurately and efficiently acquire these time-varying dynamic parameters， a dynamic cutting force prediction model considering the dynamic variation of cutting thickness is established. The vibration of the workpiece under dynamic cutting forces is equivalently modeled as a thin plate subjected to vertical in-plane excitation forces， and the initial dynamic parameters of the workpiece are calculated using the assumed mode method. Material removal and feed position variations during milling are incorporated， enabling rapid acquisition of time-varying system dynamic parameters through structural dynamic modification methods. Compared with finite element simulations， the proposed method improves computational efficiency by over 90% as it eliminates the need for repetitive modeling. Unlike experimental testing approaches， this method requires only one initial measurement experiment without interrupting the in-process parameter measurements. Experimental results demonstrate significant changes in frequency response function curves and natural frequencies during material removal， with maximum frequency variations reaching 25%. The maximum prediction error between the proposed method and experimental measurements is 4.816%.
Weida LOU , Guohua QIN , Min WAN , Zhixiang ZHU . Prediction and experimental verification of time-varying dynamic parameters for milling thin-walled workpieces[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2025 , 46(14) : 431540 -431540 . DOI: 10.7527/S1000-6893.2025.31540
| [1] | ALTINTAS Y. Manufacturing automation： metal cutting mechanics， machine tool vibrations， and CNC design［M］. Cambridge： Cambridge University Press， 2012： 125-126. |
| [2] | LI Z M， SONG Q H， JIN P J， et al. Chatter suppression techniques in milling processes： a state of the art review［J］. Chinese Journal of Aeronautics， 2024， 37（7）： 1-23. |
| [3] | REN S， LONG X H， MENG G. Dynamics and stability of milling thin walled pocket structure［J］. Journal of Sound and Vibration， 2018， 429： 325-347. |
| [4] | 廖文和， 郑侃， 孙连军， 等. 大型复杂构件机器人加工稳定性研究进展［J］. 航空学报， 2022， 43（1）： 026061. |
| LIAO W H， ZHENG K， SUN L J， et al. Review on chatter stability in robotic machining for large complex components?［J］. Acta Aeronautica et Astronautica Sinica， 2022， 43（1）： 026061 （in Chinese）. | |
| [5] | HAO Y P， ZHU L D， QIN S Q， et al. On-machine inspection and compensation for thin-walled parts with sculptured surface considering cutting vibration and probe posture［J］. International Journal of Extreme Manufacturing， 2024， 6（6）： 065602. |
| [6] | ZHU L D， LIU C F. Recent progress of chatter prediction， detection and suppression in milling［J］. Mechanical Systems and Signal Processing， 2020， 143： 106840. |
| [7] | WAN M， WANG Y T， ZHANG W H， et al. Prediction of chatter stability for multiple-delay milling system under different cutting force models［J］. International Journal of Machine Tools and Manufacture， 2011， 51（4）： 281-295. |
| [8] | WANG X J， SONG Q H， LIU Z Q. Dynamic model and stability prediction of thin-walled component milling with multi-modes coupling effect［J］. Journal of Materials Processing Technology， 2021， 288： 116869. |
| [9] | YANG Y， ZHANG W H， MA Y C， et al. Chatter prediction for the peripheral milling of thin-walled workpieces with curved surfaces?［J］. International Journal of Machine Tools and Manufacture， 2016， 109： 36-48. |
| [10] | ZHANG X J， XIONG C H， DING Y， et al. Stability analysis in milling of thin-walled workpieces with emphasis on the structural effect［J］. Proceedings of the Institution of Mechanical Engineers， Part B： Journal of Engineering Manufacture， 2010， 224（4）： 589-608. |
| [11] | ZHENG Y W， ZHAO Z C， XU B D， et al. A method to predict chatter stability accurately in milling thin-walled parts by considering force-induced deformation［J］. Journal of Manufacturing Processes， 2023， 106： 552-563. |
| [12] | ALTINTAS Y， BUDAK E. Analytical prediction of stability lobes in milling［J］. CIRP Annals， 1995， 44（1）： 357-362. |
| [13] | INSPERGER T， STEPAN G. Semi-discretization method for delayed systems［J］. International Journal for Numerical Methods In Engineering， 2002， 55（5）： 503-518. |
| [14] | DING Y， ZHU L M， ZHANG X J， et al. A full-discretization method for prediction of milling stability［J］. International Journal of Machine Tools and Manufacture， 2010， 50（5）： 502-509. |
| [15] | DING Y， ZHU L M， ZHANG X J， et al. Numerical integration method for prediction of milling stability?［J］. Journal of Manufacturing Science and Manufacturing， 2011， 133（3）： 031005. |
| [16] | LOU W D， QIN G H， LAI X C， et al. On accurate and efficient judgment method of milling stability based on predictor-corrector scheme?［J］. International Journal of Precision Engineering and Manufacturing， 2023， 24（11）： 1915-1932. |
| [17] | NIU J B， DING Y， ZHU L M， et al. Runge-Kutta methods for a semi-analytical prediction of milling stability［J］. Nonlinear Dynamics， 2014， 76： 289-304. |
| [18] | 刘春景， 唐敦兵， 陈兴强， 等. 基于改进完全离散化法铣削系统稳定性研究［J］.机械工程学报， 2023， 59（15）： 162-173. |
| LIU C J， TANG D B， CHEN X Q， et al. Research on stability of milling system based on updated complete discretization method［J］. Journal of Mechanical Engineering， 2023， 59（15）： 162-173 （in Chinese）. | |
| [19] | ZHANG X M， DING H. Note on a novel method for machining parameters optimization in a chatter-free milling process?［J］. International Journal of Machine Tools and Manufacture， 2013， 72： 11-15. |
| [20] | COMAK A， BUDAK E. Modeling dynamics and stability of variable pitch and helix milling tools for development of a design method to maximize chatter stability［J］. Precision Engineering， 2017， 47： 459-468. |
| [21] | 娄维达， 秦国华， 王华敏， 等. 基于复化Cotes积分和神经网络的稳定铣削工艺参数多目标优化方法［J］. 机械工程学报， 2023， 59（17）： 279-290. |
| LOU W D， QIN G H， WANG H M， et al. Multi-objective Optimization method of stable milling process parameters based on bp neural network and composite cotes integration［J］. Journal of Mechanical Engineering， 2023， 59（17）： 279-290 （in Chinese）. | |
| [22] | ADETORO O， SIM W， WEN P. An improved prediction of stability lobes using nonlinear thin wall dynamics［J］. Journal of Materials Processing Technology， 2010， 210（6-7）： 969-979. |
| [23] | THEVENOT V， ARNAUD L， DESSEIN G， et al. Influence of material removal on the dynamic behavior of thin-walled structures in peripheral milling?［J］. Machining Science and Technology， 2006， 10（3）： 275-287. |
| [24] | NA M. Structural dynamic modification of vibrating systems［J］. Applied and Computational Mechanics， 2007，1：203-214. |
| [25] | BUDAK E， TUNC L T， ALAN S， et al. Prediction of workpiece dynamics and its effects on chatter stability in milling［J］. CIRP Annals， 2012， 61（1）： 339-342. |
| [26] | LI Z L， TUYSUZ O， ZHU L M， et al. Surface form error prediction in five-axis flank milling of thin-walled parts?［J］. International Journal of Machine Tools and Manufacture， 2018， 128： 21-32. |
| [27] | MESHREKI M， ATTIA H， KOVECSES J. Development of a new model for the varying dynamics of flexible pocket-structures during machining?［J］. Journal of Mechanical Science and Engineering， 2011， 133（4）： 041002. |
| [28] | AHMADI K. Finite strip modeling of the varying dynamics of thin-walled pocket structures during machining［J］. The International Journal of Advanced Manufacturing Technology， 2017， 89： 2691-2699. |
| [29] | SONG Q H， SHI J H， LIU Z Q， et al. A time-space discretization method in milling stability prediction of thin-walled component?［J］. The International Journal of Advanced Manufacturing Technology， 2017， 89： 2675-2689. |
| [30] | SONG Q H， LIU Z Q， WAN Y， et al. Application of Sherman-Morrison-Woodbury formulas in instantaneous dynamic of peripheral milling for thin-walled component［J］. International Journal of Mechanical Sciences， 2015， 96： 79-90. |
| [31] | REN S， LONG X H， QU Y G， et al. A semi-analytical method for stability analysis of milling thin-walled plate［J］. Meccanica， 2017， 52： 2915-2929. |
| [32] | SUN Y W， JIANG S L. Predictive modeling of chatter stability considering force-induced deformation effect in milling thin-walled parts［J］. International Journal of Machine Tools and Manufacture， 2018， 135： 38-52. |
| [33] | LI W T， WANG L P， YU G. Force-induced deformation prediction and flexible error compensation strategy in flank milling of thin-walled parts［J］. Journal of Materials Processing Technology， 2021， 297： 117258. |
| [34] | 王志学， 刘献礼， 李茂月， 等. 考虑力致变形影响的薄壁件铣削多点接触稳定性预测［J］. 机械工程学报， 2022， 58（17）： 309-320. |
| WANG Z X， LIU X L， LI M Y， et al. Multi-point contact stability prediction considering force-induced deformation effect in milling thin-walled parts［J］. Journal of Mechanical Engineering， 2022， 58（17）： 309-320 （in Chinese）. | |
| [35] | GE G Y， DU Z C， YANG J G. Rapid prediction and compensation method of cutting force-induced error for thin-walled workpiece?［J］. The International Journal of Advanced Manufacturing Technology， 2020， 106： 5453-5462. |
| [36] | DUN Y C， ZHU L D， WANG S H. Multi-modal method for chatter stability prediction and control in milling of thin-walled workpiece［J］. Applied Mathematical Modelling， 2020， 80： 602-624. |
| [37] | HAO Y P， ZHU L D， YAN B L， et al. Milling chatter detection with WPD and power entropy for Ti-6Al-4V thin-walled parts based on multi-source signals fusion［J］. Mechanical Systems and Signal Processing， 2022， 177： 109225. |
| [38] | DUN Y C， ZHU L D， YAN B L， et al. A chatter detection method in milling of thin-walled TC4 alloy workpiece based on auto-encoding and hybrid clustering［J］. Mechanical Systems and Signal Processing， 2021， 158： 107755. |
| [39] | 王涛， 高雪峰， 祝景萍， 等. 机器人纵扭超声铣边颤振在线监测方法［J］. 航空学报， 2023， 44（13）： 427919. |
| WANG T， GAO X F， ZHU J P， et al. Chatter online monitoring of robotic longitudinal-torsional ultrasonic edge trimming［J］. Acta Aeronautica et Astronautica Sinica， 2023， 44（13）： 427919 （in Chinese）. | |
| [40] | 李超， 张俊， 田辉， 等. 综合振动信号能量比和幅值标准差的铣削颤振实时监测方法［J］. 机械工程学报， 2024， 60（14）： 11-23. |
| LI C， ZHANG J， TIAN H， et al. Timely chatter detecting method in milling with integrated energy ratio and amplitude standard deviation of vibration signal［J］. Journal of Mechanical Engineering， 2024， 60 （14）： 11-23 （in Chinese）. | |
| [41] | RAO S S. Vibration of continuous systems［M］. Hoboken： John Wiley & Sons， 2019： 258-260， 457-465. |
| [42] | ZIENKIEWICZ O， TAYLOR R， ZHU J. The finite element method： its basis and fundamentals［M］. Amsterdam： Elsevier， 2005： 4-26. |
/
| 〈 |
|
〉 |
CJA