Collaborative Research: Unified Three-Dimensional Dynamic Modeling for Drilling and Milling Tool Assemblies (STaRC-3D)

该合作研究项目的研究目标是推导和集成(1)SPECTRUM-Tchebychev技术，用于建模钻头/立铣刀动力学，包括实际的凹槽几何形状和刀架；以及(2)扩展容纳式耦合子结构分析技术，用于将刀架动态连接到主轴-机床动态。实现这一目标的方法包括四项主要任务。首先，使用SPECTRUM-Tchebychev技术推导出具有实际横截面几何形状和扭转以及夹持器的铣刀和钻具的三维动力学(扭转/轴向和弯曲耦合)的统一模型。其次，将扩展容纳子结构分析方法，使其能够预测三维扭转、轴向和非轴对称弯曲动力学。第三，刀柄动力学将与主轴-机床动力学相耦合。第四，综合方法将得到实验验证。如果成功，这项工作将通过提供一种新的分析框架来准确和高效地预测钻削/铣削刀架-主轴-机床组件的扭转/轴向和非轴对称耦合弯曲动力学，从而推动钻削/铣削模型界的发展。这种能力目前还不存在，当模式测试不方便(测量生产环境中的许多刀具)或不可能(扭矩测量钻杆-主轴-机床响应或微尺度刀具动力学)时，需要这种能力。对装配动力学的了解将使我们能够先验地选择优化的操作参数，这将立即应用于航空航天行业(一架波音747飞机有130万个钻孔)和美国经济(12.6万家美国公司使用2台铣床，雇用100万名机械师、程序员和相关人员)。

The research objective of this collaborative research project is to derive and integrate (1) the spectral-Tchebychev technique for modeling drill/endmill dynamics, including the actual fluted geometry, and holders; and (2) the extended receptance coupling substructure analysis technique, for joining tool-holder dynamics to spindle-machine dynamics. The approach to meet this objective includes four primary tasks. First, unified models for three-dimensional dynamics (coupled torsional/axial and bending) of milling and drilling tools, with actual cross-sectional geometry and twist, and holders will be derived using the spectral-Tchebychev technique. Second, the receptance coupling substructure analysis method will be extended to enable the prediction of three-dimensional torsional, axial, and non-axisymmetric bending dynamics. Third, the tool-holder dynamics will be coupled to the spindle-machine dynamics. Fourth, the integrated approach will be verified experimentally. If successful, this work will advance the drilling/milling modeling community by making available a new analytical framework for predicting the coupled torsional/axial and non-axisymmetric bending dynamics of drilling/milling tool-holder-spindle-machine assemblies in an accurate and numerically efficient fashion. This capability does not currently exist and is necessary when modal testing is inconvenient (measurement of many tools in production environments) or impossible (torsional measurements of twist drill-holder-spindle-machine responses or micro-scale tool dynamics). Knowledge of the assembly dynamics will enable a priori selection of optimized operating parameters, which will have immediate application to the aerospace industry (a Boeing 747 airplane has 1.3 million drilled holes) and the US economy (126,000 US companies use 2 milling machine tools and employ 1 million machinists, programmers, and related personnel).