Chatter stability analysis and prediction for elliptical ultrasonic vibration-assisted milling process

Elliptical ultrasonic vibration-assisted milling (EUVAM) introduces ultrasonic frequency vibration into conventional milling (CM) to achieve high-frequency intermittent milling. It has broad application prospects in processing difficult-to-cut materials such as titanium alloys, superalloys, carbon f...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology Vol. 133; no. 5-6; pp. 2937 - 2950
Main Authors: Li, Zhongqun, Yang, Shangzhen, Liu, Qiang, Liu, Hong, Liu, Yang
Format: Journal Article
Language:English
Published: London Springer London 01.07.2024
Springer Nature B.V
Subjects:
Algorithms
Brittle materials
CAE) and Design
Carbon fiber reinforced plastics
Computer-Aided Engineering (CAD
Dynamic models
Engineering
Industrial and Production Engineering
Industrial applications
Mechanical Engineering
Media Management
Milling (machining)
Numerical methods
Original Article
Runge-Kutta method
Stability analysis
Stability lobes
Stability tests
Superalloys
Titanium alloys
Titanium base alloys
Ultrasonic vibration
Vibration analysis
Workpieces
Bisection algorithm
Elliptical ultrasonic vibration assisted milling
Stability lobe diagram
Runge-Kutta based fully discrete method
ISSN:0268-3768, 1433-3015
Online Access:Get full text
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Summary:Elliptical ultrasonic vibration-assisted milling (EUVAM) introduces ultrasonic frequency vibration into conventional milling (CM) to achieve high-frequency intermittent milling. It has broad application prospects in processing difficult-to-cut materials such as titanium alloys, superalloys, carbon fiber-reinforced plastic (CFRP), and hard and brittle materials. This study focuses on the development of a dynamic model for EUVAM that considers regenerative effects and analyzes the interaction between the cutting edge and the workpiece in both radial and tangential directions, and the dynamic chip thickness is derived based on this model. To solve the model, a Runge-Kutta-based fully discrete method (RKFDM) is employed. This numerical method accurately predicts the stability of the EUVAM process under specified cutting conditions. In addition, a bisection algorithm is utilized to construct the stability lobe diagram of EUVAM, enhancing the computational efficiency of the process. Stability tests are conducted to validate the proposed stability model and solution method for EUVAM. The results of these tests confirm the accuracy and reliability of the approach presented in this paper. This study provides valuable insights and a practical framework for implementing EUVAM in the processing of difficult-to-cut materials, offering improved machining performance in various industrial applications.
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ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-024-13889-x