SGER: High-Speed Milling Dynamics

这一小型探索性研究(SGER)项目旨在探索开发一种统一的力学模型来预测高速铣削过程中的颤振；特别是对于具有柔性刀具和柔性工件的系统。开发的模型将包括时间延迟效应和接触损失效应，并将考虑工具与工件部分啮合等特征。稳定性信息将通过使用来自非线性动力学领域的工具获得。将对该模型进行分析和数值研究，以确定主轴转速和轴向切割深度等参数的稳定性图表，并检查这些图表对进给速度和进给方向的敏感性。将进行实验以验证模型预测。开发该模型所涉及的一个潜在风险是缺乏用于高速铣削操作的现成的切削力数据。如果成功，该模型的开发将对模拟工件与刀具的相互作用、选择加工参数和重新设计刀具，以解决重要的工业问题，如长端铣刀T形加强筋和回转法兰的加工以及难加工材料的加工产生巨大影响。

This Small Grant for Exploratory Research (SGER) project is to explore the development of a unified mechanics model for prediction of chatter during high-speed milling; in particular, for systems with flexible tools and flexible workpieces. The developed model will include time-delay effects and loss of contact effects, and it will allow for features such as partial engagement of a tool with the workpiece. Stability information will be obtained by using tools from the nonlinear dynamics area. This model will be analytically and numerically studied to determine stability charts in terms of parameters such as spindle speed and axial depth of cut and the sensitivity of these charts to feed rate and feed direction will be examined. Experiments will be conducted to validate the model predictions. A potential risk involved in the development of the model is due to the lack of readily available cutting force data for high-speed milling operations. If successful, the development of this model will have a tremendous impact on simulating workpiece-tool interactions, selecting machining parameters, and redesigning tools for important industrial problems such as the machining of T-shaped stiffeners and return flanges with long end mills and the machining of difficult-to-machine materials.