Professional Documents
Culture Documents
Shangxian Zhang
zhqunli @163.com
jinbu613 @sohu.com
I.
INTROD UCTION
1438
A.
Coordinate Systems
A coordinate system is set up with the direction from the
centre of the cutter bottom to the intersection point of bottom
edge with the side edge of one insert on the lower row as the
negative direction of the Yaxis, and the axis of the cutter with
the Z axis. Once the location of one insert on the lower row
has been defined in the coordinate system, the location of
others on the same row can be defined by coordinate
transformation round the Z axis; Similarly, once the initial
location of one insert on the upper row has been defined, the
location of others on the same row at any time can be defined.
The geometry of an odd-numbered insert of 6-flute tee
slotting cutter is shown in Fig.2. The cutting edge is made up
of three parts: the bottom edge CE, the side edge SF and the
circular segment edge EF. Point D is the centre of the circular
segment, 13 is the included angle of the bottom edge with the
negative direction of the Y axis, J is the included angle
between the plane of the cutting edge and the YZ plane, R is
the radius of the cutter, W is the width of the insert, h is the
height of the insert and r is the radius of the circular segment.
Z
. (
B=arcsm
hmz
+~11z + PIPzl
)
(5)
z
~m.z +~z + Pl ~m~ +~ + P~
where {m], n], pd and {m2' n2, P2} are the directional vector
of line AC and AS respectively . The points of tangency E and
F can be given by (6).
XE=sinj3 'r /tan(B /2) {Xl' =sinJ 'r /tan(B /2)
YE =cosj3r /tan(B /2)
YF =-R
(6)
ZE =0
ZF =cosJr /tan(B /2)
The perpendicular relationship of the normal vector of the
cutting edge with both the vector AC and ED makes
ED = ACxn
(7)
As a result, the centre point D of the circular segment can
be expressed as
XD
= xE
+ m3 r / ~~ + ~ + P~
YD = YE + 11:J r / ~~ + ~ + P~
{
(8)
ZD = ZE+ P3 r / ~~ + ~ + P~
where {m3' n3, P3} is the directional vector of line DE and can
be given by (7). The equation of the circular segment is
(1)
k]
cos zi
0
III.
(2)
(9)
I r; = r:
(t)
j =O
(11)
N- I
(4)
1439
where
It is the
UJ
0 is the
(12)
Fx
angular immersion
j=1 1=1
{ g( j) = 0,
tAt ~ j ~
j < tAt or j > ex
IdztanfJ
R
j=1 1=1
} =1,3,5, ...
H -ldz tan fJ
j1 =qJ+p(j-l)+atan(
R
) }=2,4,6, ...
(14)
(19)
The initial conditions Xo and Xo are presumed known as
xo = x(O) = 0
{ X = x(O) = 0
o
(20)
equations
x=- q
{ if = j(x,q,t)
(21)
Fz = LLg(j1)dFaj
(13)
(18)
j=1 1=1
j1
tool and workpiece vibrations for the current and the previous
tooth passing period, c and w represent the cutter and the
workpiece respectively, g( 0) is a unit step function which
determines whether the tooth is in or out of the cut. If st and
ex represent the entry and exit angles of the cutter to and from
the cutting, respectively, g( 0) can be determined as
g(j) = 1,
(17)
1440
this time are gotten by (21). Repeat the above process, the
solution of the dynamic equation of the machining system in
time-domain can be achieved.
V. CHATTER DETECTION CRITERION
Using the time-domain simulation proposed in the above
section, the dynamic cutting forces and the tool-workpiece
vibrations can be predicted from the inputs of the cutting
conditions, tool geometry, the dynamic characteristics of the
milling system and the work material properties. For
assessment and optimization of the cutting conditions, a
stability detection criterion is required.
It is proposed that the once per tooth revolution data is
sampled and the statistical variance of the signal was
calculated as the chatter detection criterion, which is
I)
(24)
-6
X 10
- - Direction X
- - - Di rection Y
~ 1.
etang ............
10'''' 0- 1
TOolllllale-nal
Worlq:lI ,celrll~lmal
1<Jc(Nlmm"2]
~
~
Kr.!Wmml
~
C2.C]
~
l n dAnll' n
A.Ioal RilkeAnlllen
~
~
~
[]
C:=J
l(a t>(NImm]
C:::J
.&.w:iaIOepltlof Cul(mml
l<ht{NImm)
Krc(Nlmm"2]
TOOl RadluslmmJ
InserlWi<llto[mm]
I . . . .707SfTS I
l<;Jc(NImm"21
500
Tool Ib.noo..t
Tool Mo<IeI
~Mode~
1.....-
c==::J
c==::J
Simul~onParametl"
[0"'''''
[]
2000
250 0
c==::J
1500
Frequency 1 Hz
~To;do-~
oes
1000
1441
cutter, which may result from the spindle tilt or the runout of
the teeth. Moreover, these two figures show that under the
same chip load, the cutting force normal to the feed direction
for up milling is much less than that for down milling.
.::
600
.::
~ -100
"'
600
.::
~ 500
><
fl.
.!
0.1
0.15
o !.lIUtIU!.IIJ.4Il!lIl~iJiIM
o
0.05
0 .1
0.15
0 .2
(b) Measured F,
800
fl.
600
il'
"E
400
"
u 200
0.05
0 .1
0.15
0 .10
0.15
!
s
0 .2
Time /s
Time /s
0.0
~ -0.0
:> -0.0
0.05
0.1
0 .15
0 .05
Time /s
0 . 01
6
'";ri
.~
0 .0
>:
0 . 00
O'-----~--~--~--~--~
10
13
16
Axi a l Depth of Cu t
-600
B -600
19 20
f mm
Fig .8 Tool vibration in Y direction vs. axial depth of cut under the same MRR
(n =5400 rlmin, Vf=2000 mm/min, MRR= 40 crn'zmin, up milling)
0 .0
6'
6'
o
"j"
-3
0.00
~ -0.00
.Q
~ -2
t>
-0 .0
0. 1
0.15
0 .05
- -- -0. 1
0 .15
Time /s
Time /s
~ -200
0. 15
0 .0
.~
0.1
Time /s
(a) Up Milling
(b) Down Milling
Fig.7 Simulation result to reveal a cutt ing process is stable or not
(n = 5400 rlmin, Vr= 2000 mm/min, a p = 20 mm , a c = 1.5 mm)
0.05
- 4 00 i
0 .15
0.0
-0.01"---
.~
0 .1
:~
:; -0.00
(a) Up Milling
(b) Down Millin g
Fig .9 Comparison of vibr ation of down milling with that of up milling
(n = 5400 rlmin, ap =20 mm, a,= 0.5 mm, Vf =2000 mm/m in)
c,
"'
0 .00
><
~ -200
!
s
.::
0 .05
Time /s
.Q
0.2
-~
(c) Predicated F,
(d) Measured F,
Fig.5 Cutting force Comparison for down milling
(n = 4900 rlmin, Vr= 1500 mm/min, a p = 10 mm , a c = 3 mm)
.::
0 .15
0 .0
0.05
0 .2
0 .1
Time /s
(a) Predicated F,
- 3 00
(d) Measured F,
(c) Predicated F,
Fig.6 Comparison of simulated and measured cutting force for up milling
(n = 4900 rim in, Vr = 1500 mm/min, a p = 10 mm , a c = 3 mm)
200
0 .2
a
Time /s
Time /s
<,
0 .05
300
100
0.05
-200
-400'-----~-~-~-~
400
.~
-400
VIII. CONCLUSIONS
- 8 0 0 WlL--'J....L-'.J..J.-'.J..J....LLJ...LLJLJ...LLLLL
0 .05
0. 1
0.15
0 .2
0. 10
0 .15
0.2
Time /s
Time /s
(a) Predicated
0 .05
/.~
(b) Measured F,
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[1]
1443