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Experimental investigation on the multiple vibration characteristics of milling based on spectrum feature and surface topography analysis

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Abstract

The intricate nature of milling vibrations stems from the existence of multiple vibration characteristics, encompassing free vibrations, chatter, and forced vibrations. The stiffness of the workpiece and cutting tool dramatically affects the milling vibration states where the stiffness variation can change the vibration states. This paper presents a comprehensive investigation on the effect of stiffness variation on milling vibration state for the first time. A intrinsic feature based on the spectrum characteristics and surface topography is extracted to distinguish the multiple vibration states, namely normal, chatter, and forced vibrations, across three types of milling scenarios: i) high stiffness workpiece and low stiffness tool; ii) low stiffness workpiece and high stiffness tool; and iii) both high stiffness. The vibration base frequency serves as an inherent feature, eliminating the need for setting thresholds based on different machining conditions. Milling experiments for each vibration type were performed in 28 sets at different spindle speeds and depths of cut. The results affirm that the proposed features accurately discern free vibrations, chatter, and forced vibrations across all three types of milling. Furthermore, it is found that there is a direct correspondence between the vibration base frequency of each vibration condition and the resulting surface topography. Notably, only chatter produces a new vibration base frequency, whereas the vibration base frequencies of normal and forced vibrations coincide with the spindle pass frequency.

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Acknowledgments

This work is supported by Tianjin Technical Innovation Guidance Special Foundation (No. 22YDTPJC00110), National Natural Science Foundation of China (No. 51705362), and Tianjin Research Innovation Project for Postgraduate Students (2021YJSB233). We would like to thank the Analytical & Testing Center of Tiangong University for scanning electron microscope.

Funding

This work is supported by Tianjin Technical Innovation Guidance Special Foundation (No. 22YDTPJC00110), National Natural Science Foundation of China (No. 51705362), and Tianjin Research Innovation Project for Postgraduate Students (2021YJSB233). We would like to thank the Analytical & Testing Center of Tiangong University for scanning electron microscope.

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Authors and Affiliations

  1. Tianjin Key Laboratory of Advanced Mechatronics Equipment Technology, School of Mechanical Engineering, Tiangong University, Tianjin, 300387, China

    Lei Gao, Chang Liu, Zhaoxin Hou & Weiwei Xu

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  1. Lei Gao
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  2. Chang Liu
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  3. Zhaoxin Hou
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  4. Weiwei Xu
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Contributions

LG contributed to Investigation, Methodology, Validation, Writing–original draft, and Writing–review & editing. CL contributed to Methodology, Writing–original draft, Writing–review & editing, and Supervision. ZH contributed to Experiments. WX contributed to Experiments and Data curation.

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Correspondence to Chang Liu or Weiwei Xu.

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The authors declare that they have no competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

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Technical Editor: Jarir Mahfoud.

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Gao, L., Liu, C., Hou, Z. et al. Experimental investigation on the multiple vibration characteristics of milling based on spectrum feature and surface topography analysis. J Braz. Soc. Mech. Sci. Eng. 46, 234 (2024). https://doi.org/10.1007/s40430-024-04814-0

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