Trochoidal milling is known for its advantages in machining difficult-to-machine materials as it facilitates chip removal and tool cooling.However,the conventional trochoidal tool path presents challenges such as lowe...Trochoidal milling is known for its advantages in machining difficult-to-machine materials as it facilitates chip removal and tool cooling.However,the conventional trochoidal tool path presents challenges such as lower machining efficiency and longer machining time due to its time-varying cutter-workpiece engagement angle and a high percentage of non-cutting tool paths.To address these issues,this paper introduces a parameter-variant trochoidal-like(PVTR)tool path planning method for chatter-free and high-efficiency milling.This method ensures a constant engagement angle for each tool path period by adjusting the trochoidal radius and step.Initially,the nonlinear equation for the PVTR toolpath is established.Then,a segmented recurrence method is proposed to plan tool paths based on the desired engagement angle.The impact of trochoidal tool path parameters on the engagement angle is analyzed and coupled this information with the milling stability model based on spindle speed and engagement angle to determine the desired engagement angle throughout the machining process.Finally,several experimental tests are carried out using the bull-nose end mill to validate the feasibility and effectiveness of the proposed method.展开更多
The Blade Integrated Disk(Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutte...The Blade Integrated Disk(Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutter in the rough machining of a blisk channel, the trochoidal milling is a promising strategy since it can keep a small immersion angle in the rough milling process while maintaining the high machining efficiency. However, while toolpaths are being planned for the trochoidal milling process, the conventional methods are mainly for the planar machining area with fixed tool orientations, which cannot be used for complex channels where the multi-axis machining should be employed. To this end, this paper presents a four-axis trochoidal toolpath planning method with a ball-end cutter, and thus the blisk channel can be machined efficiently.For this to happen, the trochoidal paths are planned in the parametric domain and then mapped into the physical domain, with tool orientations controlled by the quaternion interpolation method to have smooth tool movement along the toolpaths. Both geometric simulation and physical milling experiments of the proposed method have convincingly demonstrated the validation of the proposed method.展开更多
This paper shows that a turned trochoidal function disturbance may lead to peripheral drops production. The resulting model is used to describe that a turned trochoidal disturbance leads to peripheral drops production...This paper shows that a turned trochoidal function disturbance may lead to peripheral drops production. The resulting model is used to describe that a turned trochoidal disturbance leads to peripheral drops production on the liquid jet surface without the necessity for superimposed disturbances. The trochoid is a non-unique parametric function. Only non-unique parametric functions disturbances may lead to peripheral drops production. The trochoidal function disturbance is decomposed to Fourier series. Every Fourier element receives an amplification factor in accordance to the Rayleigh inviscid jet model. Peripheral drops are received on the jet surface. The paper shows that all trochoidal disturbance functions, prolate cycloid, cycloid and curtate cycloid have a capability of peripheral drops producing. A limited capability of peripheral drops production is introduced for the trochoidal curtate cycloid. Produced drops size are reduced for increasing the jet velocity and wave number. Smaller drops are also received by transition from the prolate cycloid to curtate cycloid disturbance.展开更多
基金supported by the National Natural Science Foundation of China(Grant Nos.U22A20202 and 52275477).
文摘Trochoidal milling is known for its advantages in machining difficult-to-machine materials as it facilitates chip removal and tool cooling.However,the conventional trochoidal tool path presents challenges such as lower machining efficiency and longer machining time due to its time-varying cutter-workpiece engagement angle and a high percentage of non-cutting tool paths.To address these issues,this paper introduces a parameter-variant trochoidal-like(PVTR)tool path planning method for chatter-free and high-efficiency milling.This method ensures a constant engagement angle for each tool path period by adjusting the trochoidal radius and step.Initially,the nonlinear equation for the PVTR toolpath is established.Then,a segmented recurrence method is proposed to plan tool paths based on the desired engagement angle.The impact of trochoidal tool path parameters on the engagement angle is analyzed and coupled this information with the milling stability model based on spindle speed and engagement angle to determine the desired engagement angle throughout the machining process.Finally,several experimental tests are carried out using the bull-nose end mill to validate the feasibility and effectiveness of the proposed method.
基金supported by the China National Science and Technology Major Project(No.2015ZX04001202)
文摘The Blade Integrated Disk(Blisk) is one of the key components in the aero-engine, it is generally manufactured by the multi-axis milling and almost 90% raw materials are removed. To avoid the full immersion of a cutter in the rough machining of a blisk channel, the trochoidal milling is a promising strategy since it can keep a small immersion angle in the rough milling process while maintaining the high machining efficiency. However, while toolpaths are being planned for the trochoidal milling process, the conventional methods are mainly for the planar machining area with fixed tool orientations, which cannot be used for complex channels where the multi-axis machining should be employed. To this end, this paper presents a four-axis trochoidal toolpath planning method with a ball-end cutter, and thus the blisk channel can be machined efficiently.For this to happen, the trochoidal paths are planned in the parametric domain and then mapped into the physical domain, with tool orientations controlled by the quaternion interpolation method to have smooth tool movement along the toolpaths. Both geometric simulation and physical milling experiments of the proposed method have convincingly demonstrated the validation of the proposed method.
文摘This paper shows that a turned trochoidal function disturbance may lead to peripheral drops production. The resulting model is used to describe that a turned trochoidal disturbance leads to peripheral drops production on the liquid jet surface without the necessity for superimposed disturbances. The trochoid is a non-unique parametric function. Only non-unique parametric functions disturbances may lead to peripheral drops production. The trochoidal function disturbance is decomposed to Fourier series. Every Fourier element receives an amplification factor in accordance to the Rayleigh inviscid jet model. Peripheral drops are received on the jet surface. The paper shows that all trochoidal disturbance functions, prolate cycloid, cycloid and curtate cycloid have a capability of peripheral drops producing. A limited capability of peripheral drops production is introduced for the trochoidal curtate cycloid. Produced drops size are reduced for increasing the jet velocity and wave number. Smaller drops are also received by transition from the prolate cycloid to curtate cycloid disturbance.
