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Optimization method of spindle speed with the consideration of chatter and forced vibration for five-axis flank milling

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Abstract

Spindle speed optimization is important for the machining industry to improve the material removal rate (MRR). However, low spindle speeds are always used to avoid inaccuracy caused by the chatter and forced vibration. Especially for the five-axis flank milling, the selection of spindle speeds is conservative since the complexity of the tool-workpiece engagement (TWE) and the corresponding dynamics. This paper presents a spindle speed optimization method to improve MRR with the consideration of chatter and forced vibration for five-axis flank milling. Chatter and forced vibration models of five-axis flank milling are developed based on the general cutting dynamics model. The root-mean-square (RMS) values of the forced vibration displacement are employed to evaluate the surface quality. The relationship between the stable spindle speed and the forced vibration reveals that the surface quality is positively associated with the spindle speed in some specific ranges, and MRR is improved by increasing the spindle speed in those ranges without the risk of increasing inaccuracy. The simulation results and experimental work show that the proposed method can be used to optimize spindle speeds for improving MRR without inducing chatter and aggressive forced vibration.

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Funding

This research was funded by the National Key R&D Program of China (No. 2018YFB1701901) and Shaanxi Science Foundation for Distinguished Young Scholars (2019JC08) for Jun Zhang.

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Authors and Affiliations

  1. State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an, 710054, Shaanxi Province, People’s Republic of China

    Yuyang Tang, Jun Zhang & Wanhua Zhao

  2. AVIC Xi’an Aircraft Industry Group Company Ltd., Xi’an, 710089, Shaanxi Province, People’s Republic of China

    Hui Tian

  3. Arts et Metiers Institute of Technology, LaBoMaP, Université Bourgogne Franche-Comté, HESAM Université, Rue Porte de Paris, 71250, Cluny, France

    Hongguang Liu

Authors
  1. Yuyang Tang
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  2. Jun Zhang
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  3. Hui Tian
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  4. Hongguang Liu
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  5. Wanhua Zhao
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Contributions

Y. Tang: methodology, data curation, formal analysis, writing-original draft, review and editing. J. Zhang: conceptualization, supervision, funding acquisition, writing-review and editing. H. Tian: validation, writing-review and editing. H. Liu: writing-review and editing. W. Zhao: conceptualization, supervision, writing-review and editing.

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Correspondence to Jun Zhang.

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Tang, Y., Zhang, J., Tian, H. et al. Optimization method of spindle speed with the consideration of chatter and forced vibration for five-axis flank milling. Int J Adv Manuf Technol 125, 3159–3169 (2023). https://doi.org/10.1007/s00170-023-10894-4

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  • DOI: https://doi.org/10.1007/s00170-023-10894-4

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