Improving dynamic process stability in finishing of thin-walled workpieces by optimal selection of stock shape

Procedia CIRP, vol. 126, pp. 372–377

Abstract

In 5-axis milling of thin-wall parts, flexibility of the in-process-workpiece (IPW) governs static and dynamic deflections, especially at the semi-finishing and finishing stages. Thus, the near net shape preform, i.e. the stock shape left for semi/finishing is crucial for chatter stability. In this study, a methodology is presented to design the stock shape for improved stability. Coupled process simulation, which includes material removal, finite element analysis (FEA) and process stability simulations, is used to show the effect of stock shape on chatter stability. Spindle speed is optimized along the toolpath based on the varying process dynamic behavior for selected cutter locations (CL). The proposed method is experimentally demonstrated on case studies.

Authors 6

1. Pascal Kienast corresponding Aachen Fraunhofer Institute for Production Technology IPT

   Fraunhofer Institute for Production Technology IPT

   Affiliation as printed

   Fraunhofer Institute for Production Technology IPT, Steinbachstr. 17, 52074 Aachen, Germany

2. Lütfi Taner Tunç

   Sabancı Üniversitesi

   Affiliation as printed

   Manufacturing Research Lab, Faculty of Engineering and Natural Sciences, Sabanci University, 34956 Istanbul, Türkiye

3. Recep Koca

   Turkish Aerospace Industries (Turkey)

   Affiliation as printed

   TUSAS Engine Industries Inc. (TEI), 26210 Eskişehir, Türkiye

4. Ozan Ölgü

   Turkish Aerospace Industries (Turkey)

   Affiliation as printed

   TUSAS Engine Industries Inc. (TEI), 26210 Eskişehir, Türkiye

5. Philipp Ganser Aachen Fraunhofer Institute for Production Technology IPT

   Fraunhofer Institute for Production Technology IPT

   Affiliation as printed

   Fraunhofer Institute for Production Technology IPT, Steinbachstr. 17, 52074 Aachen, Germany

6. Thomas Bergs Aachen Fraunhofer Institute for Production Technology IPT Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University · Fraunhofer Institute for Production Technology IPT

   Affiliation as printed

   Fraunhofer Institute for Production Technology IPT, Steinbachstr. 17, 52074 Aachen, Germany

   Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, Germany