Application of adaptive mashining force to workpiece-fixture dynamic behavior according to material removal effects

Abstract

Surface quality is a major factor affecting the performance of a component. The machined surface quality is strongly influenced by degree of stability during the fixturing and machining processes. In machining process development, it is highly desirable to optimum the quality of a machined surface and its dynamic response. The primary goal of this paper is to investigate the dynamic behaviors and surface quality of the verified workpiece-fixture design against the clamping and periodic cutting forces (helical end milling) with the application of frictional contact and chip removal effects using a finite-element technique and the secondary goal is to adapt and change the cutting force cycle and spindle speed along the cutting tool path according to the dynamic responses of workpiece-fixture systems and the maximum elastic deformation of workpiece during machining. The harmonic and modal analysis is carried out for numerical simulated cutting forces cycle to recognize the dynamic effects of chip removal, machining force and its dominant excitation frequency on stability, dynamic responses of workpiecfixture and elastic deformation of workpiece under finite-element based model. Cutting forces cycle are numerically simulated according to the geometry and other properties of cutter .the chip removal effects and frictional contact between the
workpiece and the fixture elements are taken into account using a material removal approach based on element death technique and nonlinear finite-element analysis.