Influence of unilateral constraint on machining dynamics of large overhang milling cutter

• Published in: International journal of advanced manufacturing technology Vol. 125; no. 7-8; pp. 3577 - 3591
• Main Authors: Meng, Fangting, Song, Qinghua, Peng, Yezhen, Liu, Zhanqiang
• Format: Journal Article
• Language: English
• Published: London Springer London 01.04.2023; Springer Nature B.V
• Subjects: Advanced manufacturing technologies; Boundary conditions; CAE) and Design; Cantilever beams; Computer-Aided Engineering (CAD; Deformation; Dynamic models; Dynamic stability; Efficiency; Engineering; Industrial and Production Engineering; Investigations; Manufacturing; Mechanical Engineering; Media Management; Milling (machining); Morphology; Original Article; Parameters; Shear forces; Workpieces; Large overhang milling cutter; Stability; Dynamics; Unilateral constraint
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-023-11028-6

The large overhang milling cutter is widely used in machining deep concave parts in aerospace equipment. Due to the large length-diameter ratio, vibration and deformation can occur easily in the machining process with a large hanging milling cutter. In this paper, the influence of unilateral constraint on machining characteristics of the large overhang milling cutter is considered, where the constraint is generated from the obstruction of workpiece. Firstly, the dynamic model of the large overhanging milling cutter with unilateral constraint is established according to the cantilever beam theory. The nonlinear boundary conditions for the balance between internal shear force and top surface force are given. Then, the influence of unilateral constraint on the surface morphology of workpiece, and that of dynamic parameters on milling stability are investigated. The results show that the final machined surface is composed of morphologies with multiple deformation periods of the cutter. Unilateral constraint further affects the milling stability by changing the modal parameters of the cutter. Finally, some modal tests and milling experiments are conducted to verify the law of the unilateral constraint. The experimental results show that the modal parameters of the milling cutter with unilateral constraint change obviously and the stability prediction considering unilateral constraint is more accurate.