Adjustment of cutting modes based on the data of numerical simulation of a tool-workpiece system dynamics taking into account resonances
https://doi.org/10.21285/1814-3520-2020-5-993-1006
Abstract
The purpose of the work is to adjust the cutting modes for the manufacturing process of the Cover-Bracket part, which are set in accordance with the recommendations of the electronic catalog CoroPlus ToolGuide by the tool manufacturer Sandvik. This correction is required in order to improve the dynamic stability of machining. The problem of cutting mode adjustment is solved through the use of the methods of numerical simulation of the tool-workpiece system dynamics with regard to the resonances in the Femap engineering analysis program with Nastran. Recommendations are given for cutting modes taking into account the technical capabilities of the machine-tool and tooling, as well as the volume of the material removed with no reference for the dynamic properties of the tool and machine-tool. It is shown that at the 7th and 8th technological transitions the resonant vibrations are observed in the milling tool-workpiece system and the ratio of forces on the cutting edges of milling tools changes up to 245%, which leads to their uneven wear and decreases machining quality. It is found out that the oscillations of the processing forces can be represented as a sum of several harmonics of the rotational and tooth mesh frequencies. The results obtained show that the problem of deviation from the resonant frequencies can be solved not only by lowering the spindle speed, but also by changing the manufacturing process. Recommended change in the sequence of the technological transitions 7 and 8 allows to avoid resonance frequencies without reducing the performance level and machine at the maximum permissible cutter speed of 18,000 rpm. Under this approach, the first harmonics of the tooth mesh frequencies will be outside the resonant zone. In the future, it is planned to supplement the model with the dynamic characteristics of the machine-tool, tool and equipment.
About the Authors
P. N. Kostin
Irkutsk National Research Technical University
Russian Federation
Russian Federation
Pavel N. Kostin, Postgraduate Student
83 Lermontov St., Irkutsk 664074
A. V. Lukyanov
Irkutsk State Transport University
Russian Federation
Russian Federation
Anatoly V. Lukyanov, Dr. Sci. (Eng.), Professor, Professor of the Department of Physics, Mechanics and Instrument Making
15 Chernyshevsky St., Irkutsk 664074
D. P. Aleinikov
Irkutsk National Research Technical University
Russian Federation
Russian Federation
Dmitry P. Aleinikov, Cand. Sci. (Eng.), Associate Professor of the Department of Mechanical Engineering Production Technologies and Equipment
83 Lermontov St., Irkutsk 664074
References
1. Aleynikov DP, Lukyanov AV. Cutting forces modeling and vibration diagnostics of signs of end mills defects. Sistemy. Metody. Tekhnologii = Systems. Methods. Technologies. 2017;33:39–47. https://doi.org/10.18324/2077-5415-2017-1-39-47 (In Russ.)
2. Lukyanov AV, Aleynikov DP. Research in the space vibration of machining center in milling mode. Sistemy. Metody. Tekhnologii = Systems. Methods. Technologies. 2014;1:96–101. (In Russ.)
3. Lukyanov DA, Aleynikov DP, Luk'yanov A.V. Calculation of parameters and visualization of spatial vibrations of machining center spindle by vibration measurement results. Vestnik Irkutskogo gosudarstvennogo tehnicheskogo universiteta = Proceedings of Irkutsk State Technical University. 2013;12:92–98. (In Russ.)
4. Lukyanov AV, Aleynikov DP. Analysis of oscillations of cutting forces between a mill and a workpiece when increasing the spindle rotation speed. Sovremennye tekhnologii. Sistemnyj analiz. Modelirovanie = Modern technologies. System analysis. Modeling. 2017;56(4):70– 82. (In Russ.)
5. Kudinov VA. Machine-tool dynamics. Moscow: Mashinostroenie; 1967, 359 p. (In Russ.)
6. Savilov AV, Pyatyh AS. Vibration effect on accuracy and quality of hole surface under drilling. Vestnik Irkutskogo gosudarstvennogo tehnicheskogo universiteta = Proceedings of Irkutsk State Technical University. 2013;12:103–110. (In Russ.)
7. Savilov AV, Pjatyh AS, Timofeev SA. Machining processes optimization based on modal and dynamometric analysis. Nauka i tehnologii v promyshlennosti. 2013;1- 2:42–46. (In Russ.)
8. Altintas Yu. Manufacturing automation. Metal cutting mechanics, machine tool vibrations, and cnc design. Cambridgе: Cambridge University Press; 2012, 366 р. https://doi.org/10.1017/cbo9780511843723
9. Shanthi B, Mahalakshmi N, Shobana M. Structural health monitoring using varied machine learning algorithms. International Journal of Engineering & Technology. 2018;7(3.12):793–796. https://doi.org/10.14419/ijet.v7i3.12.16503
10. Yurkevich VV. Measurement of cutting force vertical component when turning. Metalloobrabotka. 2012;5–6:6– 8. (In Russ.)
11. Lukyanov AA, Kapustin AN, Lukyanov AV. Algorithmic and software support of automated thermomonitoring and equipment diagnostics. Kontrol'. Diagnostika = Testing. Diagnostics. 2005;9:45–53. (In Russ.)
12. Ahmadi K, Savilov A. Modeling the mechanics and dynamics of arbitrary edge drills. International Journal of Machine Tools and Manufacture. 2015;89:208–220. https://doi.org/10.1016/j.ijmachtools.2014.11.012
13. Mokrickij BYa, Sitamov ES. Selection of strengthening coatings based on simulation results. Uprochnyayushchie tekhnologii i pokrytiya. 2020;16(4):147–150. https://doi.org/10.36652/1813-1336-2020-16-4-147-150 (In Russ.)
14. Gavrilin AN, Moizes BB, Faskhutdinov RM. Modeling of processes in the manufacturing system during turning process. Glavnyi mekhanik = Chief Mechanical Engineer. 2019;4:46–50. (In Russ.)
15. Mokrickij BYa, Sitamov ES, Vereshchagin VYu, Shakirova OG. Controlling by selection of strengthened tool based on modeling in DEFORM software environment. Uprochnyayushchie tekhnologii i pokrytiya. 2019;15(6):249–251. (In Russ.)
16. Gimadeev MR, Davydov VM. Ensuring quality of a surface when mechanoprocessing figurine details. Tekhnologiya mashinostroeniya. 2018;11:9–16. (In Russ.)
17. Kozochkin MP, Sabirov FS, Bogan AN, Myslivcev KV. Monitoring of process equipment for industrial enterprises. Vestnik UGATU. 2013;17(8):56–62. (In Russ.)
18. Grigorjev SN, Gurin VD, Kozochkin MP. Diagnostics of automated production. Moscow: Mashinostroenie; 2011, 600 p. (In Russ.)
19. Ignatjev SA, Ignatjev AA, Ivaschenko VA. Automated systems of monitoring of the technical condition of technological equipment. Mekhatronika, avtomatizatsiya, upravlenie = Mechatronics, automation, control. 2009;8:43–47. (In Russ.)
20. Sastry S, Kapoor SG, Devor RE. Floquet theory based approach for stability analysis of the variable speed face-milling process. Journal of Manufacturing Science and Engineering. 2002;124(1):10–17. https://doi.org/10.1115/1.1418695
21. Drachev OI. Technology of vibration processing and vibration turning of low-rigid parts. Series: Quality management of technological processes in mechanical engineering. Irbit: Ob’edinenie nauchnyh inzhenernyh kommercheskih struktur; 2015, 260 р. (In Russ.)
Review
For citations:
Kostin P.N., Lukyanov A.V., Aleinikov D.P. Adjustment of cutting modes based on the data of numerical simulation of a tool-workpiece system dynamics taking into account resonances. Proceedings of Irkutsk State Technical University. 2020;24(5):993-1006. (In Russ.) https://doi.org/10.21285/1814-3520-2020-5-993-1006
Views:
260
Email this article 