Release Time:2019-03-12  Hits:

Indexed by: Journal Article

Date of Publication: 2018-06-01

Journal: CHINESE JOURNAL OF AERONAUTICS

Included Journals: SCIE

Volume: 31

Issue: 6

Page Number: 1375-1387

ISSN: 1000-9361

Key Words: Cutting force; Floquet theory; Milling stability; Multi-delay milling system; Run-out

Abstract: In this paper, a multi-delay milling system considering helix angle and run-out effects is firstly established. An exponential cutting force model is used to model the interaction between a work-piece and a cutting tool, and a new approach is presented for accurately calibrating exponential cutting force coefficients and cutter run-out parameters. Furthermore, based on an implicit multi-step Adams formula and an improved precise time-integration algorithm, a novel stability prediction method is proposed to predict the stability of the system. The involved time delay term and periodic coefficient term are integrated as a comprehensive state term in the integral response which is approximated by the Adams formula. Then, a Floquet transition matrix with an arbitrary-order form is constructed by using a series of matrix multiplication, and the stability of the system is determined by the Floquet theory. Compared to classical semi-discretization methods and full-discretization methods, the developed method shows a good performance in convergence, efficiency, accuracy, and multi-order complexity. A series of cutting tests is further carried out to validate the practicability and effectiveness of the proposed method. The results show that the calibration process needs a time of less than 5 min, and the stability prediction method is effective. (C) 2017 Production and hosting by Elsevier Ltd. on behalf of Chinese Society of Aeronautics and Astronautics.