Papers by Author: Qing Hua Song

Abstract: The first step to predict the milling stability is to identify the dynamic characteristics of cutting process. And the mass loading effects of removal material play an important role on the dynamic characteristics of milling process for thin-walled parts, such as impeller, turbine blades and automobile components, which is changing with cutting time or tool position. Therefore, how to identify the instantaneous dynamic characteristics of milling process is one of the most significant problems. In the paper, a structural dynamic modification method with variable mass to predict the instantaneous dynamic characteristics of multi-axis milling thin-walled workpiece with complex curved surface is proposed. The proposed method takes into account the variations of dynamics characteristics of workpiece with the tool position and material removal. And the material cutting process is regarded as the structural dynamic modifications of cutting system, the instantaneous dynamic characteristics of which can be estimated by the extended Sherman-Morrison-Woodbury formula to obtain the corrected frequency response function (FRF). Experiments were carried out to obtain the instantaneous dynamics of a thin-walled workpiece and the results were verified by finite element method (FEM).

Abstract: The ecological structures of some organisms that could resist environmental vibration naturally (such as dragonfly, woodpecker and legs of cursorial animals) uncovered by biologists inspire people a new approach to overcome the above problem. In this paper, a new shock isolation system consisting of a pedestal, a rubber layer, an air spring and a shearing viscoelastic damper is designed, fabricated, and characterized to avoid the performance deterioration and physical damage of mechanical manufacturing devices from external mechanical excitations. The nonlinear dynamics model of the platform is developed and the dynamic characteristics are analyzed using numerical analysis. The displacement and velocity response are obtained. The results demonstrate that the stiffness and damping characteristic of the platform change with excitation frequency. The vibration isolation effectiveness will be greatly enhanced.

Abstract: A generalized cutting mechanics model is proposed for milling processes with solid end mills and inserted cutters. The unified mathematical model is employed for the description of the solid milling flute and insert on a reference tool body. The friction and normal forces acting on the rake face are transformed into milling coordinates using a general transformation matrix by simply assigning operation specific parameters. The generalized model can be used to predict and optimize the machining operations including solid end mills and inserted cutters.

Abstract: An alternative physical explanation for process damping where a distributed cutting force model, along with a function distribution over the tool-chip interface, is assumed, is described. An exponential shape function is used to approximate the force distribution on the tool-chip interface. The distributed force model results in a more complicated governing equation, a second-order delayed integrodifferential equation, which involves both a discrete and distributed delay. An approach to transform and normalize the governing equation of motion into a third-order discrete system is described and the state-space representation of the new system is obtained. The semi-discretization method is then used to chart the stability boundaries for turning operation.

Abstract: High-speed milling (HSM) has advantages in high productivity high precision and low production cost. Thus it can be widely used in the manufacture industry. However, when the speed of spindle-tool reaches a higher speed range, the gyroscopic effect will become an important part of its stable milling. In this paper, a dynamics model of HSM system was proposed considering the influence of gyroscopic moment due to high rotating speed of end milling. Finite element model (FEM) is used to model the dynamics of a spindle-milling system. It obtains the trajectory of central point in face milling with considering gyroscopic effects through the dynamics model at high speeds. Then the cutting force model will be corrected by the trajectory of face milling. Then the stability lobes diagrams (SLD) was elaborated. Cutting thickness effects have non-negligible impact on stability limitation.

Abstract: The efficiency of the high-speed milling process is often limited by the occurrence of chatter. In order to predict the occurrence of chatter, accurate models are necessary. With the speed increasing, gyroscopic effect plays an important pole on the system behavior, including dynamic characteristic and rotating behavior. Considering the influence of gyroscopic effect on rotating behavior, an updated model for the milling process is presented which features as model of the equivalent profile of tool. In combination with this model, a nonlinear instantaneous cutting force model is proposed. The use of this updated equivalent profile of tool results in significant differences in the static uncut thickness compared to the traditional model.

Abstract: High-speed milling (HSM) has advantages in high productivity high precision and low production cost. Thus it can be widely used in the manufacture industry. However, when the speed of spindle-tool reaches a higher speed range, the gyroscopic effect will become an important part of its stable milling. In this paper, a dynamics model of HSM system was proposed considering the influence of gyroscopic moment due to high rotating speed of end milling. Finite element model (FEM) is used to model the dynamics of a spindle-milling system. It obtains the trajectory of central point in face milling with considering gyroscopic effects through the dynamics model at high speeds. Then the cutting force model will be corrected by the trajectory of face milling. So it can provide a basis for stability prediction of high speed milling.

Abstract: Vibration frequencies during high-speed milling processes are investigated. Based on the resonant theory and three critical stats of phase position of successive two cutter teeth, six kinds of spindle speeds are shown, which divide the stable region in stability limit diagram into four parts. Furthermore, using optimal control theory, a novel stable region is proposed, which divides the region into three parts (unconditional stable, optimal stable, and conditional stable region).