Double-sided milling of thin-walled parts by dual collaborative parallel kinematic machines
Double-sided milling of thin-walled parts by dual collaborative parallel kinematic machines
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DOI：
10.1016/j.jmatprotec.2021.117395
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发表时间：
2022-01
影响因子：
6.3
通讯作者：
R. Fu;P. Curley;Colm Higgins;Z. Kilic;D. Sun;A. Murphy;Yan Jin
中科院分区：
文献类型：
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作者：
R. Fu;P. Curley;Colm Higgins;Z. Kilic;D. Sun;A. Murphy;Yan Jin
具有双面特征的薄壁零件广泛应用于许多工业部门，但其加工特别耗时且具有挑战性。协同加工是工业4.0发展的新范式。它可能会彻底改变现有的薄壁零件加工方法，从而提高生产率，灵活性和可持续性。为此，本文介绍了一种新的概念与双并联机床（PKM）协同执行同步和并行化的切割和支持从两侧的薄壁零件，没有转换/重新夹紧的工件。研究表明，与传统的单面加工相比，双并联机床协同操作下工件的静态和动态性能得到了显著改善。以双面特征薄壁零件为例，采用并联机床进行了双面同步铣削、交替单面铣削和顺序单面铣削三种加工策略的对比研究。实验结果表明，双并联机床的双面同步铣削策略提高了机床的静态刚度和动态性能，并平衡了工件的变形，从而获得了最佳的尺寸精度和满意的表面质量。更重要的是，由于新策略将材料去除率提高了一倍，同时消除了传统单面加工中使用的繁琐的过程步骤，因此生产率提高了两倍。
Thin-walled parts with double-sided features are widely used in many industrial sectors but their machining is particularly time consuming and challenging. Collaborative machining is a new paradigm in the development of industrial 4.0. It can potentially revolutionize the existing thin-walled part machining methods, leading to higher productivity, flexibility and sustainability. For this end, this paper introduces a novel concept with dual parallel kinematic machines (PKMs) collaboratively performing synchronized and asynchronized cutting and support from both sides of a thin-walled part, without changeover/re-clamping of the workpiece. Compared to the conventional single-sided machining, this study shows that static and dynamic performances of the workpiece are significantly improved under the dual PKM collaborative operation. A case study of milling a thin-walled part with double-sided features was conducted by PKMs under three comparative strategies, namely, double-sided synchronized milling, alternative single-sided milling, and sequential single-sided milling. Experimental results show that the novel double-sided synchronized milling strategy by dual collaborative PKMs produced the best dimensional accuracy and satisfactory surface quality due to the improved static stiffness and dynamic performance, and balanced deflections. More importantly, a two-fold greater productivity has been achieved as the novel strategy doubles the material removal rate while eliminating the cumbersome in-process steps used in conventional single-sided machining.