Yuanyuan Jiang, Jingwei Li, Yanling Li, Dapeng Tian, and Xinli Yu
Milling, surface morphology, tool runout, workpiece deformation,optimisation parameters
In the context of processing titanium alloy thin-walled parts, tool runout and workpiece deformation are commonly observed due to their low rigidity. Therefore, it is crucial to comprehensively assess the combined impact of these factors on surface quality. This study proposes a surface topography model that incorporates tool runout and workpiece deformation. Initially, the influence of workpiece material and milling force is disregarded, and the movement path of the tool tip is analysed by modifying key parameters such as spindle speed, feed speed, and tool diameter. By applying the principle of reflection, the resulting geometric shape and texture of the machined surface are determined. Subsequently, a surface topography model is developed by integrating tool runout and workpiece deformation. Simulation results are utilised to investigate the effects of different milling parameters on surface roughness. To validate the accuracy of the established surface topography model, various milling parameters are selected based on a machining stability prediction model, targeting stable milling and chatter milling. When flutter occurs, it not only amplifies variations in surface topography but also exacerbates the vibration of the thin-walled workpiece, leading to the emergence of sawtooth stripes on the surface. Consequently, flutter adversely affects surface quality. The workpiece’s surface roughness is measured, and a comparison and analysis are conducted between the predicted surface roughness values obtained through simulation and those measured experimentally. Finally, a genetic algorithm is employed to optimise machining parameters while considering efficiency, resulting in the attainment of optimal milling parameters and achieving desirable surface quality without chatter. The selected parameters adhere to the constraint of maximum force ∗ School of Mechanical Engineering, Liaoning Petro- chemical University, Fushun 113001, China; e-mail: [email protected]; [email protected]. ∗∗ Sinopec (Dalian) Petrochemical Research Institute Co., Ltd, Dalian 116041, China; e-mail: [email protected]. ∗∗∗ Power Operation Department of Liaoyang Petro- chemical Company, Liaoyang 111003, China; e-mail: [email protected]. ∗∗∗∗ China Petroleum and Chemical Corporation (Guangdong) Refining and Chemical Co., Ltd, Zhanjiang 524000, China; e-mail: [email protected]. Corresponding Author: Yuanyuan Jiang and mitigate the occurrence of chatter. In summary, the optimised processing parameters effectively meet the practical requirements of the machining process, providing valuable insights for practical machining applications.
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