Stability prediction of thin-walled workpiece made of Al7075 in milling based on shifted Chebyshev polynomials

Zhenghu Yan, Zhibing Liu*, Xibin Wang, Biao Liu, Zhiwen Luo, Dongqian Wang

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

14 Citations (Scopus)

Abstract

With the rapid development of aerospace technology, Al7075 has been widely used for structural components. High-speed milling is one of the most effective ways to improve machining efficiency of Al7075. During the milling process, regenerative chatter which restricts the milling quality and productivity often occurs. With the aim of avoiding regenerative chatter, stability lobe diagram (SLD) is widely used to obtain chatter-free parameters. This work presents a stability prediction method by using shifted Chebyshev polynomials. The milling dynamics with consideration of the regenerative effect is described by time periodic delay-differential equations (DDEs). The transition matrix of the milling system is constructed with the help of Chebyshev–Gauss–Lobatto (CGL) points. In order to demonstrate the accuracy of the proposed method, the rate of convergence of the proposed method is compared with that of the classical benchmark methods. On the other hand, in the process of thin-walled workpiece milling, the dynamic behavior of the workpiece depends on the tool position. To study the influence of the tool position dependent dynamics on the chatter stability of the thin-walled workpiece, a three-dimensional SLD is obtained. The verification experiments are conducted to verify the reliability of the proposed method. The results show that the experimental results are consistent with the predicted results.

Original languageEnglish
Pages (from-to)115-124
Number of pages10
JournalInternational Journal of Advanced Manufacturing Technology
Volume87
Issue number1-4
DOIs
Publication statusPublished - 1 Oct 2016

Keywords

  • Chebyshev polynomials
  • Milling stability
  • Position dependent dynamics
  • Thin-walled workpiece

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