Liu Xiaoli, Liu Dexuan, Du Canyang, Li Yang, Wang Caidong, Fu Zhijun
College of Mechanical and Electrical Engineering, Zhengzhou University of Light Industry, Zhengzhou 450002, China.
Henan Provincial Key Laboratory of Intelligent Manufacturing of Mechanical Equipment, Zhengzhou 450002, China.
Micromachines (Basel). 2024 Feb 6;15(2):244. doi: 10.3390/mi15020244.
During micro-milling, regenerative chatter will decrease the machining accuracy, destabilize the micro-milling process, shorten the life of the micro-mill, and increase machining failures. Establishing a mathematical model of chatter vibration is essential to suppressing the adverse impact of chatter. The mathematical model must include the dynamic motions of the cutting system with the spindle-holder-tool assembly and tool runout. In this study, an integrated model was developed by considering the centrifugal force induced by rotational speeds, the gyroscopic effect introduced by high speeds, and the tool runout caused by uncertain factors. The tool-tip frequency-response functions (FRFs) obtained by theoretical calculations and the results predicted by simulation experiments were compared to verify the developed model. And stability lobe diagrams (SLDs) and time-domain responses are depicted and analyzed. Furthermore, experiments on tool-tip FRFs and micro-milling were conducted. The results validate the effectiveness of the integrated model, which can calculate the tool-tip FRFs, SLDs, and time responses to analyze chatter stability by considering the centrifugal force, gyroscopic effect, and tool runout.
在微铣削过程中，再生颤振会降低加工精度，使微铣削过程不稳定，缩短微铣刀寿命，并增加加工失败率。建立颤振振动的数学模型对于抑制颤振的不利影响至关重要。该数学模型必须包括带有主轴-刀柄-刀具组件的切削系统的动态运动以及刀具跳动。在本研究中，通过考虑转速引起的离心力、高速引入的陀螺效应以及不确定因素导致的刀具跳动，开发了一个综合模型。将理论计算得到的刀尖频率响应函数（FRF）与模拟实验预测的结果进行比较，以验证所开发的模型。并绘制和分析了稳定性叶瓣图（SLD）和时域响应。此外，还进行了刀尖FRF和微铣削实验。结果验证了综合模型的有效性，该模型可以通过考虑离心力、陀螺效应和刀具跳动来计算刀尖FRF、SLD和时间响应，以分析颤振稳定性。
