Milling Stability Research Based On Cutting Force Simulation And Precise Integration Method

Manufacture is one of the important industry systems for the national economic growth. It has been developing rapidly in the world. Based on the complete theoretical system and long-term practical experience, the development of advanced manufacture has faced the more challenges. As the advanced science and electrical and electronic technology improving, information intelligent control technology has applied on the mechanical manufacturing. It aimed to be an intelligence, automation, information technology and high-precision production system. Milling is one of the most common processing methods in the mechanical manufacture industry. The stability of milling process is the key of manufacture technology. The actual milling vibration problem has seriously affected the accuracy and quality of parts, efficiency and even security. In recent years, high-precision, high-quality parts manufacture becomes a problem, so selecting the appropriate cutting parameters in machining process has great significance to improve the accuracy and quality of parts.Considered the stability of processing system and based on analyzing the vibration of processing system, this paper makes a research on the chatter and stability of milling to optimize the process parameters and improve the quality of parts.First of all, based on the zero-order analytical (ZOA), combined the modal testes and cutting force experiments, the chatter stability lobes diagram can be built.Then considered the feasibility of practical project and reliable identification of cutting force coefficients, it is appropriate to apply the finite element method (FEM). The actual cutting process can be simulated, and the cutting force and chip formation can be obtained. Through the analysis of cutting force and force data processing, the cutting force coefficients can be obtained.After that, combined the cutting force coefficients and the machine tool system modal parameters, based on the PTSIM, the kinetic equations can be calculated considered the non-linear time delay factors in time domain. At last, the chatter stability lobes diagram of cutting parameters selection can be obtained.Through the above studies, the theory in this paper improves the stability of milling process. The method of higher accurate milling parameters selection has been proposed based on the original theory in time domain. After verification, it can be applied on the practical projects. It is important value to make a research on the process chatter theory, and it also can optimize the dynamic theory in the cutting processing. Because the milling is a common method to cutting parts, this paper can be applied widely in the practical mechanical industry. Combined the rapid calculation and the high-precision calculation, the result based on the dynamic theory will be more accurate and practical. Cutting dynamics model theory can be optimized by precise time step integration method (PTSIM) and numerical solver. Based on the PTSIM, building the chatter stability lobes diagram of cutting parameters selection can improve the quality, accuracy and efficiency directly and rapidly. The proposed method modifies the non-linear dynamic model theory and the accuracy of the chatter stability lobes diagram of cutting parameters selection, and it has been verified.