Time Domain Simulation with Applications in Compliant Workpiece Milling

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Rubeo, M. (2016). Time Domain Simulation with Applications in Compliant Workpiece Milling. Unc Charlotte Electronic Theses And Dissertations.
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Abstract

High performance application fields, such as the defense, power, and aerospace industries, benefit from the enhanced product quality and reduced cost associated with machining thin-walled, metallic structures over traditional fabrication and assembly methods (e.g., sheet metal buildups). The mechanical properties of difficult-to-machine materials, such as titanium and nickel alloys, make them ideal candidates for compliant, thin-walled structures. Near net shape techniques have been used to manufacture compliant structures composed of hard-to-machine materials, but these techniques are often unable to achieve the required dimensional tolerances and surface finishes. Due to the inherent compliance of the preforms, stable machining is difficult to achieve. Prediction of stable machining parameters is therefore critical for the finish machining of such compliant workpieces.In this research, a time domain simulation is presented for predicting stable and unstable milling conditions with application to finish milling of compliant workpieces. Traditional lobe diagrams provide global stability predictions by dividing the domain of spindle speed and chip width into stable and unstable regions. Time domain simulation provides local information (forces, displacements, etc.) for individual spindle speed-chip width combinations. Stability metrics, based on the local information, are developed to extend the utility of the time domain simulation to provide the global stability predictions of traditional lobe diagrams. The time domain simulation global stability predictions and "local" information are validated experimentally.

Details
Author

Rubeo, Mark

Title

Time Domain Simulation with Applications in Compliant Workpiece Milling

Physical Description

1 online resource (158 pages) : PDF

Date

2016

Degree Granting Institution

University of North Carolina at Charlotte

Abstract

High performance application fields, such as the defense, power, and aerospace industries, benefit from the enhanced product quality and reduced cost associated with machining thin-walled, metallic structures over traditional fabrication and assembly methods (e.g., sheet metal buildups). The mechanical properties of difficult-to-machine materials, such as titanium and nickel alloys, make them ideal candidates for compliant, thin-walled structures. Near net shape techniques have been used to manufacture compliant structures composed of hard-to-machine materials, but these techniques are often unable to achieve the required dimensional tolerances and surface finishes. Due to the inherent compliance of the preforms, stable machining is difficult to achieve. Prediction of stable machining parameters is therefore critical for the finish machining of such compliant workpieces.In this research, a time domain simulation is presented for predicting stable and unstable milling conditions with application to finish milling of compliant workpieces. Traditional lobe diagrams provide global stability predictions by dividing the domain of spindle speed and chip width into stable and unstable regions. Time domain simulation provides local information (forces, displacements, etc.) for individual spindle speed-chip width combinations. Stability metrics, based on the local information, are developed to extend the utility of the time domain simulation to provide the global stability predictions of traditional lobe diagrams. The time domain simulation global stability predictions and "local" information are validated experimentally.

Genre

doctoral dissertations

Subjects--Topics

Mechanical engineering

Degree

Ph.D.

Keywords

Chatter
Compliant
Flexible
Milling
Simulation

Subject Area

Mechanical Engineering

Advisor(s)

Schmitz, Tony

Committee Members

Smith, Scott
Ziegert, John
Davies, Matt
Zhou, Aixi

Degree Note

Thesis (Ph.D.)--University of North Carolina at Charlotte, 2016.

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Rights Holder Information

Copyright is held by the author unless otherwise indicated.

Identifier

Rubeo_uncc_0694D_11238

Permalink

http://hdl.handle.net/20.500.13093/etd:1111