Cutting force and chatter stability analysis for PKM-based helical milling operation
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ORIGINAL ARTICLE
Cutting force and chatter stability analysis for PKM-based helical milling operation Mengrui Shi 1 & Xuda Qin 1 & Hao Li 1
&
Shuai Shang 1 & Yan Jin 2 & Tian Huang 1,3
Received: 19 February 2020 / Accepted: 15 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract In order to enhance the manufacturing productivity, mobile machining with industrial robots is proposed as a cost-effective and portable manufacturing alternative to large-scale CNC machine tools in aircraft part machining. Combing the advantages of helical milling and parallel robot, the cutting forces and chatter stability of a novel 5-DOF hybrid PKM (named TriMule)-based helical milling process are first investigated in this paper. The cutting force and dynamic model of PKM-based helical milling operation are proposed, and the chatter stability diagrams at the seven representative machining positions are obtained based on the complete discretization scheme with Euler’s method approach. The predicted cutting forces and chatter stability diagrams are experimentally validated by the PKM-based titanium alloy helical milling. It can be found that the PKM machining position has a great influence on the corresponding limit stable axial depth of cut in the helical milling operation. Meanwhile, it was indicated that the spindle speed is an important factor affecting the helical milling stability difference at different machining positions. Meanwhile, it was found that the helical milling stability is only determined by second-, third-, and fourth-order modes of TriMule when the spindle speed is higher than 1000 rpm with the first 4 modes of the cutting system considered. The research results are expected to provide a basis for the helical milling parameter optimization and reasonable robot machining position selection. Keywords PKM . Helical milling . Cutting force . Complete-discretization method . Stability lobe diagram
* Hao Li [email protected]
Nomenclature Fx, Fy, Fz kx, ky, kz
Mengrui Shi [email protected]
F
Xuda Qin [email protected]
Ff
Shuai Shang [email protected]
h(θi)
Yan Jin [email protected]
db dSi Fa, Fr, Ft
Tian Huang [email protected] 1
Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Tianjin 300072, China
2
School of Mechanical and Aerospace Engineering, Queen’s University Belfast, Belfast BT5 9AH, UK
3
School of Engineering, University of Warwick, Coventry CV4 7AL, UK
Krc, Ktc, Kac
Kre, Kte,Kae
Cutting forces applied by the end effector Stiffness of PKM end effector along the direction of cutting forces Cutting force caused by the peripheral cutting edges Cutting force caused by the front cutting edges Undeformed thickness of cutting chip of the tooth i Differential width of cut Differential edge length Cutting forces in the directions of axial, radial, and tangential Cutting force coefficients associated with the thickness of cutting chips which are named shear effect coefficients for the radial, tangential, and axi
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