Investigation of tool flank wear effect on system stability prediction in the milling of Ti-6AI-4 V thin-walled workpiece

被引:10
作者
Ma, Junjin [1 ]
Li, Yunfei [1 ]
Zhang, Dinghua [2 ]
Zhao, Bo [1 ]
Yan, Xinhong [1 ]
Pang, Xiaoyan [3 ]
机构
[1] Henan Polytech Univ, Sch Mech & Power Engn, Jiaozuo 454000, Henan, Peoples R China
[2] Northwestern Polytech Univ, Key Lab Contemporary Design & Integrated Mfg Tech, Minist Educ, Xian 710072, Peoples R China
[3] Henan Polytech Univ, Coll Comp Sci & Technol, Jiaozuo 454000, Henan, Peoples R China
基金
中国国家自然科学基金;
关键词
Tool wear; Dynamic cutting force; Process damping; Stability prediction; Ti-6AI-4; V; MECHANISTIC MODEL; CUTTING FORCES; CHATTER;
D O I
10.1007/s00170-022-10136-z
中图分类号
TP [自动化技术、计算机技术];
学科分类号
0812 ;
摘要
Excessive tool wear can shorten tool life and cause low machining surface quality and efficiency in the milling of Ti-6AI-4 V thin-walled workpieces. The influence mechanism between the tool flank wear and stability predication is of significant for its further development in milling Ti-6Al-4 V. However, the relationship between tool flank wear and stability predication needs to be further investigated as the effect of time-varying tool flank wear is ignored in conventional methods. In this work, a system stability prediction model considering time-varying tool flank wear effect in milling of Ti-6AI-4 V thin-walled workpiece is proposed. The tool flank wear region is discretized into differential elements, and then, the friction effect and process damping effect caused by extruding function between tool and workpiece are analyzed, and a time-varying milling force model is established. In this process, the relationship of cutting tool flank wear band width VB and section radius difference NB is determined, and the indentation volume between tool and workpiece is iteratively calculated, which is used to investigate process damping. After, the time-varying milling force coefficients are derived considering different tool flank wear status. Then, in modal space, the evolutionary process of stability lobe diagrams considering tool flank wear effect is determined. Subsequently, to effectively predict system stability, tool flank wear curves and dynamic cutting force coefficients are calibrated by slot milling, and the average errors between cutting force prediction values considering tool flank wear effect and experimental values in feed direction and normal direction are 7.3% and 12.1%, respectively. Finally, a series of machining tests are conducted to verify the effectiveness of tool flank wear on the machining stability in the milling of Ti-6AI-4 V thin-walled workpieces to some extent, and the experimental results show that the system stability prediction accuracy of the proposed method is improved by 23.8% compared with that using conventional method.
引用
收藏
页码:3937 / 3956
页数:20
相关论文
共 34 条
[1]   Effects of micro-milling conditions on the cutting forces and process stability [J].
Afazov, S. M. ;
Zdebski, D. ;
Ratchev, S. M. ;
Segal, J. ;
Liu, S. .
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY, 2013, 213 (05) :671-684
[2]   Analytical stability lobes including nonlinear process damping effect on machining chatter [J].
Ahmadi, K. ;
Ismail, F. .
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE, 2011, 51 (04) :296-308
[3]   Investigation into the effectiveness of cutting parameters on wear regions of the flank wear curve and associated cutting tool life improvement [J].
Altan, Erhan ;
Uysal, Alper ;
Caliskan, Oguz .
INTERNATIONAL JOURNAL OF MATERIALS & PRODUCT TECHNOLOGY, 2018, 57 (1-3) :54-70
[4]  
Altintas Y, 2012, MANUFACTURING AUTOMATION: METAL CUTTING MECHANICS, MACHINE TOOL VIBRATIONS, AND CNC DESIGN, 2ND EDITION, P1
[5]   Experimental investigation on tool wear characteristics of PVD and CVD coatings during face milling of Ti-6242S and Ti-555 titanium alloys [J].
An, Qinglong ;
Chen, Jie ;
Tao, Zhengrui ;
Ming, Weiwei ;
Chen, Ming .
INTERNATIONAL JOURNAL OF REFRACTORY METALS & HARD MATERIALS, 2020, 86
[6]   Chatter stability of a slender cutting tool in turning with tool wear effect [J].
Chiou, RY ;
Liang, SY .
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE, 1998, 38 (04) :315-327
[7]   Using tool wear to increase process stability when milling Al7075 and AISI 4140+QT [J].
Denkena, Berend ;
Krodel, Alexander ;
Relard, Andreas .
PRODUCTION ENGINEERING-RESEARCH AND DEVELOPMENT, 2021, 15 (06) :843-853
[8]   A unified process damping model considering the varying stiffness of the milling system [J].
Feng, Jia ;
Wan, Min ;
Dong, Zi-Yu ;
Zhang, Wei-Hong .
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE, 2019, 147
[9]   Mechanism of process damping in milling of thin-walled workpiece [J].
Feng, Jia ;
Wan, Min ;
Gao, Ting-Qi ;
Zhang, Wei-Hong .
INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE, 2018, 134 :1-19
[10]   Flank tool wear prediction of laser-assisted milling [J].
Feng, Yixuan ;
Hung, Tsung-Pin ;
Lu, Yu-Ting ;
Lin, Yu-Fu ;
Hsu, Chuan ;
Lin, Chiu-Feng ;
Lu, Ying-Cheng ;
Liang, Steven Y. .
JOURNAL OF MANUFACTURING PROCESSES, 2019, 43 :292-299