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Influences of modal shape and tool orientation on evolution of dynamic responses in 5-axis milling of thin-walled parts

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Abstract

Both modal shape and tool orientation affect dynamic responses of thin-walled parts. However, the influences of these two aspects on dynamic responses have not been studied simultaneously. This paper studies the influences of modal shape and tool orientation on evolution of dynamic responses during 5-axis ball-end milling of thin-walled parts. Firstly, a modal shape-based model is established to calculate the dynamic response of the workpiece, the model considers forced and regenerative effects, and it is related to the tool orientation and cutting position. Next, the acceleration signal of workpiece during machining process and the roughness of machined surface are measured. The wavelet transform is performed on the acceleration signal to identify the state of the machining process. The test results show that the proposed model can predict the trend of dynamic response with the change of the tool orientation and can predict the stability of milling processes, the dominant vibration modes of workpiece and its conversion boundary. Moreover, the interpretations are given to the effects of modal shape and tool orientation on the evolution of dominant vibration modes and dynamic response. This research can provide guidelines for optimizing tool orientations.

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Acknowledgements

This work is supported by the National Natural Science Foundation of China (No. 51775444).

Funding

This work is supported by the National Natural Science Foundation of China (No. 51775444).

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Authors and Affiliations

  1. School of Mechanical Engineering, Northwestern Polytechnical University, 127 West Youyi Road, Xi’an, Shaanxi, 710072, China

    Dazhen Wang & Junxue Ren

  2. School of Electromechanical and Automotive Engineerin, YanTai University, 30 Qingquan Road, Yantai, Shandong, 264005, China

    Dazhen Wang

  3. Training center for engineering practices, Northwestern Polytechnical University, 1 Dongxiang Road, Xi’an, Shaanxi, 710129, China

    Weijun Tian

Authors
  1. Dazhen Wang
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  2. Junxue Ren
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Contributions

Dazhen Wang: Conceptualization, Methodology, Investigation, Software, Validation, Writing - review & editing, Data curation. Junxue Ren: Project administration, Supervision, Funding acquisition. Weijun Tian: Investigation.

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Correspondence to Dazhen Wang.

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Wang, D., Ren, J. & Tian, W. Influences of modal shape and tool orientation on evolution of dynamic responses in 5-axis milling of thin-walled parts. Int J Adv Manuf Technol 119, 4485–4508 (2022). https://doi.org/10.1007/s00170-021-08565-3

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  • DOI: https://doi.org/10.1007/s00170-021-08565-3

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