Search

Featured Application: Prediction and selection of the clamping conditions of large-size workpieces for the purpose of milling, based on modal tests and milling simulations. Vibrations occurring during milling operations are one of the main issues disturbing the pursuit of better efficiency of milling operations and product quality. Even in the case of a stable cutting process, vibration reduction is still an important goal. One of the possible solutions to obtain it is selection of the favorable conditions for clamping the workpiece to the machine table. In this paper, a method for predicting and selecting the clamping condition of a large-size workpiece for the reduction in vibrations during milling is presented. A modal test of the workpiece is performed first for a selected set of tightening screw settings. Next, one milling pass is performed to obtain reference data which are then used to tune the hybrid computational model. In the subsequent step, milling simulations are performed for a set of tightening variants, and the best one is selected, providing the lowest vibrations, assessed as the root mean square (RMS) of vibration displacements. In this paper, the description of the clamping selection procedure, key elements of the simulation model, and simulation and experimental results obtained for the milling of the test workpiece performed for a set of different clamping conditions are provided. The proposed method accurately predicts not only the best but also the worst clamping conditions. [ABSTRACT FROM AUTHOR]

This paper concerns the problem of vibration reduction during milling. For this purpose, it is proposed that the standard supports of the workpiece be replaced with adjustable stiffness supports. This affects the modal parameters of the whole system, i.e., object and its supports, which is essential from the point of view of the relative tool–workpiece vibrations. To reduce the vibration level during milling, it is necessary to appropriately set the support stiffness coefficients, which are obtained from numerous milling process simulations. The simulations utilize the model of the workpiece with adjustable supports in the convention of a Finite Element Model (FEM) and a dynamic model of the milling process. The FEM parameters are tuned based on modal tests of the actual workpiece. For assessing simulation results, the proper indicator of vibration level must be selected, which is also discussed in the paper. However, simulating the milling process is time consuming and the total number of simulations needed to search the entire available range of support stiffness coefficients is large. To overcome this issue, the artificial intelligence salp swarm algorithm is used. Finally, for the best combination of stiffness coefficients, the vibration reduction is obtained and a significant reduction in search time for determining the support settings makes the approach proposed in the paper attractive from the point of view of practical applications. [ABSTRACT FROM AUTHOR]

The paper presents an original method concerning the problem of vibration reduction in the general case while milling large-size and geometrically complex details with the use of an innovative approach to the selection of spindle speed. A computational model is obtained by applying the so-called operational approach to identify the parameters of the workpiece modal model. Thanks to the experimental modal analysis results, modal subsystem identification was performed and reliable process data for simulation studies were obtained. Next, simulations of the milling process, for successive values of the spindle speed, are repeated until the best vibration state of the workpiece is obtained. For this purpose, the root mean square values of the time plots of vibration displacements are examined. The effectiveness of the approach proposed for reducing vibrations in the process of face milling is verified on the basis of the results of appropriate experimental investigations. The economic profitability of the implementation of the operational technique in the production practice of enterprises dealing with mechanical processing is demonstrated as well. [ABSTRACT FROM AUTHOR]

The paper presents a thoroughly modified method of solving the problem of vibration suppression when boring large-diameter holes in large-size workpieces. A new approach of adjusting the rotational speed of a boring tool is proposed which concerns the selection of the spindle speed in accordance with the results of the simulation of the cutting process. This streamlined method focuses on phenomenological aspects and involves the identification of a Finite Element Model (FEM) of a rotating boring tool only and validating it with a real object, while dispensing with discrete modelling of a completely rigid workpiece. In addition, vibrations in the boring process in all directions were observed, which implies a geometric nonlinearity of the process model. During the simulation, the values of the Root Mean Square (RMS) of the time plots and the dominant values of the "peaks" in the displacement amplitude spectra were obtained. The effectiveness of the method was demonstrated using a selected mechatronic design technique called Experiment-Aided Virtual Prototyping (E-AVP). It was successfully verified by measuring the roughness of the indicated zone of the workpiece surface. The economic profitability of implementing the method in the production practice of enterprises dealing with mechanical processing is also demonstrated. [ABSTRACT FROM AUTHOR]