Modelling the unidirectional fibre composite milling force oscillations through capturing the influence of the stochastic fibre distributions
Modelling the unidirectional fibre composite milling force oscillations through capturing the influence of the stochastic fibre distributions
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通过捕获随机纤维分布的影响对单向纤维复合铣削力振荡进行建模
DOI：
10.1016/j.compstruct.2019.111188
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发表时间：
2019-10
影响因子：
6.3
通讯作者：
Dragos A.Axinte
中科院分区：
文献类型：
--
作者：
梅嘉炜;Oriol GavaldaDiaz;Dragos A.Axinte
虽然高频变化的切削力是一个固有的特性，铣削复合材料时，研究和模型的解释和时域模拟这样的加工力似乎是在文献中失踪。本文首先指出复合铣削力的变化来源于三个方面：1）由切削刃摆线轨迹引起的切屑厚度的变化; 2）复合材料中纤维的随机分布; 3）由于铣刀的旋转运动引起的切削方向相对于纤维取向的连续变化。此外，刀具的螺旋角导致切削刃的每个部分同时接合不同的纤维取向，这在理解和预测合力方面增加了额外的挑战。因此，本文开发了一种分析方法，可以用来准确地模拟铣削力的时域单向纤维复合材料。该方法计算芯片的厚度，估计随机纤维的位置，并定义不同的纤维取向的可变切削系数，以整合他们的影响力的变化。此外，将螺旋铣刀离散为若干切片，模拟了各啮合部位在相应纤维切削角下的受力情况，从而得到了螺旋铣刀复合切削力的模拟过程。分别考虑直铣刀和螺旋铣刀对模型进行验证，并分别研究了这三个方面的影响，以深入了解铣削力的变化规律，为所建立的模型提供支持。当纤维的切割方向固定时，铣削力的变化服从高斯分布。此外，仿真铣削力显示出令人满意的协议与实验结果，特别是他们的振荡说明了高度的一致性。
Although high frequency variation of cutting forces is an inherent characteristic when milling composites, studies and models on the explanation and time-domain simulation of such processing forces seem to be missing in the literature. This paper first claims that the variation of the composite milling forces comes from three aspects: i) the variation of chip thickness caused by the cycloid trajectories of the cutting edge; ii) the random fibre placements within the composite and iii) the continuous variation of the cutting direction relative to the fibre orientation due to the rotational motion of the milling cutter. Moreover, the cutter’s helix angle leads to each section of the cutting edge engaging different fibre orientations simultaneously, adding additional challenges in understanding and predicting the resultant forces. Thus, this paper develops an analytical approach which can be utilised to accurately simulate the milling forces in time domain for unidirectional fibre composites. The approach calculates the chip thickness, estimates the stochastic fibre placements and defines variable cutting coefficients for different fibre orientations to integrate their effects on the force variability. Besides, the helical cutter is discretized into several slices to simulate the force acting on each engaged part at its relevant fibre cutting angle, resulting in a procedure of simulating the composite cutting force with helical milling cutter. Both straight and helical milling cutters are taken into account to validate the model, the effects from the concluded three aspects are separately investigated to provide an in-depth understanding of the force variation and support the developed model. It is observed that the variation of milling forces follows a Gaussian distribution when the cutting direction of the fibre is fixed. Furthermore, the simulated milling forces show a satisfactory agreement with the experimental results, especially their oscillations illustrate a high degree of consistency.
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DOI：
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