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整合(1)用于模拟钻头/立铣刀动力学的谱-切比切夫技术，包括实际的凹槽几何形状和刀架；(2)扩展接收耦合子结构分析技术，将刀柄动力学与主轴-机床动力学结合起来。实现这一目标的方法包括四项主要任务。首先，将使用谱- tchebychev技术推导铣削和钻井工具的三维动力学（耦合扭转/轴向和弯曲）的统一模型，并具有实际的横截面几何形状和捻度，以及夹具。其次，将扩展接收耦合子结构分析方法，以实现三维扭转、轴向和非轴对称弯曲动力学的预测。第三，刀柄动力学将耦合到主轴-机床动力学。第四，对集成方法进行实验验证。如果成功，这项工作将通过提供一个新的分析框架，以准确和数字高效的方式预测钻/铣刀架-主轴-机床组件的耦合扭转/轴向和非轴对称弯曲动力学，从而推动钻/铣建模社区。这种能力目前还不存在，当模态测试不方便（在生产环境中测量许多工具）或不可能（扭曲钻头-主轴-机器响应或微尺度工具动力学的扭转测量）时，这种能力是必要的。对装配动力学的了解将使优化操作参数的先验选择成为可能，这将立即应用于航空航天工业（一架波音747飞机有130万个钻孔）和美国经济（126,000家美国公司使用2台铣床，雇用100万机械师、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).