High Speed High Power Milling

本课题旨在对高速大功率激光器进行研究 铣削（HSHP铣削）分为以下三个相互关联的部分： 铣刀破损传感、高速铣削动力学及设计 关于HSHP 这项提议是根据 获得了国家科学基金会的资助 在铣刀传感部分 在先前的赠款中开发和测试的算法将被 使用基于切削力采样的，与 切割器齿并产生每个齿的平均值的第一差。 通过这种方法可以清楚地识别断裂， 区别于由于研磨瞬态（如进入 切. 在当前的提议中，加速度计信号将用于 通过模拟和反向传输重建力 主轴动力学 这种间接测力的方法是必要的 由于高速铣削时的刀齿频率超过了 直接测力测功机的动态响应能力。 在 关于HSHP铣削动力学的部分， 优先授予，旨在确定最动态稳定的主轴 在目前的提案中，速度将通过传感器自动化， 校准切割，以便各种操作的最佳速度， 工具将自动调整。 在HS HP设计部分 对角接触轴承副阻尼特性的空间研究， 为了将这一重要方面纳入 主轴动力学优化。 本课题的研究对于HSHP的发展具有重要意义 铣削成实用工艺。 解决这三个问题的方法是 解决的是不可用的，这些是刀具断裂检测， 自动调整到最稳定的速度，并设计动态 刚性高速高功率主轴。 HSHP铣削可应用于 铣削需要大量金属的工业部件 去除了例如在飞行器结构板上的装袋操作， 陆军武器库中的钢零件的面铣，以及铸铁的铣削 汽车零件冲压模具。

This proposal is to conduct research on high speed high power milling (HSHP Milling) in the following three interrelated parts: Sensing of Milling Cutter Breakage, Dynamics of HSHP Milling, and Design of HSHP Spindles. This proposal is based on recommendations resulting from a prior NSF grant. In the part on Sensing of Milling Cutter Breakage the algorithm developed and tested in the prior grant will be used which is based on sampling of the cutting force, synchronized with the cutter teeth and generating first differences of averages per tooth. Breakage is clearly recognized by this method and the breakage is distinguished from changes due to milling transients like entry into a cut. In the current proposal an accelerometer signal will be used to reconstruct the force through simulation and reverse transfer across the spindle dynamics. This indirect force measurement approach is necessary because the cutter tooth frequency in high speed milling is beyond the dynamic response capability of direct force measuring dynamometers. In the part on Dynamics of HSHP Milling the procedures developed in the prior grant and aimed at determining the most dynamically stable spindle speed will be automated in the current proposal by means of sensors and calibration cuts so that the optimum speed for various operations and tools will be automatically adjusted. In the part on Design of HSHP Spindles research on damping in pairs of angular contact bearings will be conducted in order to include this important aspect in the optimization of spindle dynamics. The proposed research is necessary for the development of HSHP milling into a practical process. Solutions to the three problems being addressed are not available, these being cutter breakage detection, automatic adjustment to the most stable speed, and design of dynamically rigid high speed high power spindles. HSHP milling has application to milling of industrial components where large amounts of metal has to be removed, for example pocketing operations on aircraft structural panels, face milling of steel parts in Army arsenals, and milling of cast iron stamping dies for automotive parts.