Chatter Stability Prediction And Process Optimization Of A Duplex Face Turning Machine

Lathes are used in a wide range of applications in the manufacturing industry,from everyday products to highly sophisticated aerospace products.With the development of science and technology,there are higher requirements for the precision and efficiency of processing and manufacturing of aerospace engine materials that are difficult to process.In particular,the processing of disk-like components,such as compressor disk,has always been a huge challenge due to its large diameter-to-thickness ratio(ie large diameter and small thickness),low rigidity and easy deformation.Parallel or double-sided machining can improve the metal removal rate of difficult-tocut materials.In order to solve the above problems,first of alll,a duplex machining is introduced to manufacture thin-walled disk-like parts,which allows simultaneous cutting of opposite sides to improve productivity and mitigate workpiece deformations/vibrations during machining.In addition,this article established a three-dimensional Chatter prediction model for one-sided turning,and then extended to duplex face turning.For the common single-degree-of-freedom orthogonal turning,it is relatively simple to establish the dynamic cutting chip thickness equation,and it is also possible to directly draw the stability lobe diagram.However,in this model,not only the deformation of two tools and thin-walled workpiece but also the nonlinear factors such as the tool geometry and the axial deformation converted into radial deformation are considered.After identifying the system parameters such as cutting force coefficient and modal parameters,the stability lobe diagram is obtained according to the nyquist stability criterion,and its accuracy is verified by design experiments.To a certain extent,it is revealed that a one-sided turning is only a special case of duplex face turning,and the same depth of cut on both sides is the most effective cutting method,and the total depth of cut of duplex face turning is about 1.75 times that of onesided turning.Finally,according to the three-dimensional stability lobe diagram of the duplex face turning,the compressor blank is processed into a formed part.