Chatter reliability prediction of side milling aero-engine blisk
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DOI 10.1007/s12206-020-2211-z
Journal of Mechanical Science and Technology 34 (10) 2020 Original Article DOI 10.1007/s12206-020-2211-z Keywords: · Chatter reliability · First-order second-moment method · Reliability lobe diagram · Side milling · Stability lobe diagram
Correspondence to: Nan Zhang [email protected]
Citation: Jiang, G.-J., Wu, D.-W., Zhang, N., Wu, J.-X., Wang, Y. (2020). Chatter reliability prediction of side milling aero-engine blisk. Journal of Mechanical Science and Technology 34 (10) (2020) ?~?. http://doi.org/10.1007/s12206-020-2211-z
Chatter reliability prediction of side milling aero-engine blisk Guang-Jun Jiang, Dong-Wei Wu, Nan Zhang, Jian-Xin Wu and Ying Wang School of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot 010051, China
Abstract Reliability analysis of a dynamic structural system is applied to predict chatter of side milling system for machining blisk. Chatter reliability is defined as the probability of stability for processing. A reliability model of chatter was developed to forecast chatter vibration of side milling, where structure parameters and spindle speed are regarded as random variables and chatter frequency is considered as intermediate variable. The first-order second-moment method was used to work out the side milling system reliability model. Reliability lobe diagram (RLD) was applied to distinguish reliable regions of chatter instead of stability lobe diagram (SLD). One example is used to validate the effectiveness of the proposed method and compare with the Monte Carlo method. The results of the two approaches were consistent. Chatter reliability and RLD could be used to determine the probability of stability of side milling.
Received April 24th, 2020 Revised
May 23rd, 2020
Accepted June 1st, 2020 † This paper was presented at ICMR2019, Maison Glad Jeju, Jeju, Korea, November 27-29, 2019. Recommended by Guest Editor Insu Jeon
1. Introduction Blisk is a new integral structure of blade and disk usually used in advanced aero-engines. The complicated blisk structure, which is comprised of narrow tunnels that are highly twisted and bowed, is typically manufactured using difficult-to-machine materials, such as titanium alloy or other high-temperature alloys [1-3]. Therefore, blisks are extremely difficult to manufacture. Multi-axial NC milling is widely used to process blisk. Side milling has been adopted for finishing blisk. Blisk-tunnels are deep and overhang of the cutter is large [4-7]. Therefore, chatter is prone to occur. Chatter reduces product quality, increases tool wear and limits production efficiency. It is a key issue to suppress chatter. The most effective way to avoid chatter is to use a stability lobe diagram (SLD) [8-10]. It can provide a theoretical basis for improving the processing efficiency and optimizing technology parameters in practical production. Altintas and Budak [11] proposed a fast and effective zero-order approximation method to predict stability of the milling process. This method ignores the influence of h
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