An integrated machine-process-controller model to predict milling surface topography considering vibration suppression

Abstract

Surface topography is an important factor in evaluating the surface integrity and service performance of milling parts. The dynamic characteristics of the manufacturing system and machining process parameters significantly influence the machining precision and surface quality of the parts, and the vibration control method is applied in high-precision milling to improve the machine quality. In this study, a novel surface topography model based on the dynamic characteristics of the process system, properties of the cutting process, and active vibration control system is theoretically developed and experimentally verified. The dynamic characteristics of the process system consist of the vibration of the machine tool and piezoelectric ceramic clamping system. The dynamic path trajectory influenced by the processing parameters and workpiece-tool parameters belongs to the property of the cutting process, while different algorithms of active vibration control are considered as controller factors. The milling surface topography can be predicted by considering all these factors. A series of experiments were conducted to verify the effectiveness and accuracy of the prediction model, and the results showed a good correlation between the theoretical analysis and the actual milled surfaces.

Keywords

Machine-process-controller / Milling surface topography / Vibration suppression / Prediction model

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Funding

National Natural Science Foundation of China http://dx.doi.org/10.13039/501100001809(51905347)