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

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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.

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Authors and Affiliations

  1. The Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education, Northwestern Polytechnical University, Box 552, Xi’an, Shaanxi, 710072, People’s Republic of China

    Xiaojun Lin

  2. Northwestern Polytechnical University, Xi’an, Shaanxi, 710072, People’s Republic of China

    Xiaojun Lin, Dongbo Wu, Biying Yang, Gang Wu, Xiufeng Shan & Qunbao Xiao

  3. AECC Xi’an Aero-engine LTD, Xi’an, Shaanxi, 710021, People’s Republic of China

    Liangyi Hu & Jie Yu

Authors
  1. Xiaojun Lin
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  2. Dongbo Wu
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  3. Biying Yang
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  4. Gang Wu
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  6. Qunbao Xiao
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  8. Jie Yu
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Correspondence to Xiaojun Lin.

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Lin, X., Wu, D., Yang, B. et al. Research on the mechanism of milling surface waviness formation in thin-walled blades. Int J Adv Manuf Technol 93, 2459–2470 (2017). https://doi.org/10.1007/s00170-017-0669-3

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  • DOI: https://doi.org/10.1007/s00170-017-0669-3

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