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Research on the mechanism of milling surface waviness formation in thin-walled blades

  • Xiaojun Lin
  • Dongbo Wu
  • Biying Yang
  • Gang Wu
  • Xiufeng Shan
  • Qunbao Xiao
  • Liangyi Hu
  • Jie Yu
ORIGINAL ARTICLE

Abstract

The surface waviness of blade surfaces in numerically controlled (NC) milling processes directly affects the mechanical behavior of the blade. To research the mechanism of surface waviness formation, this study utilizes wavelet analysis in investigating the measured results of surface profile. Firstly, the experiment on a #45 steel cantilever blade was performed on an NC milling machine and the vibrational signals during the milling process were analyzed by fast Fourier transform. Secondly, the first-order natural frequencies of the machine-tool system and the machine-workpiece system were obtained by modal test based on DWESOFT and simulation based on ANSYS. Thirdly, the selected optimal wavelet was applied to decompose and reconstruct each layer of the blade surface contour signal based on MATLAB. Finally, the frequency information of the wavelet, the frequency information of the milling vibration signals, and the first-order natural frequencies of the systems were compared. The maximum of the amplitude value of the milling vibration signals corresponds to the frequency 161.1 Hz, which is equivalent to the excitation frequency of the teeth by calculating and the frequency of the maximum amplitude of the second-layer profile by wavelet analysis. The modal analysis showed that the first-order natural frequencies of the machine-tool system in the x and y directions and the machine-workpiece system are 737.3, 668.9, and 542.0 Hz, respectively, which are far away from the frequencies the maximum amplitude of the each layer profile obtained by wavelet analysis. The results showed that surface waviness is caused by forced vibration in thin-blade NC milling, rather than self-excited vibration.

Keywords

Wavelet analysis Surface ripple Milling vibration Blade profile 

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Copyright information

© Springer-Verlag London Ltd. 2017

Authors and Affiliations

  • Xiaojun Lin
    • 1
    • 2
  • Dongbo Wu
    • 2
  • Biying Yang
    • 2
  • Gang Wu
    • 2
  • Xiufeng Shan
    • 2
  • Qunbao Xiao
    • 2
  • Liangyi Hu
    • 3
  • Jie Yu
    • 3
  1. 1.The Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of EducationNorthwestern Polytechnical UniversityXi’anPeople’s Republic of China
  2. 2.Northwestern Polytechnical UniversityXi’anPeople’s Republic of China
  3. 3.AECC Xi’an Aero-engine LTDXi’anPeople’s Republic of China

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