A novel asymmetric milling method toward high-performance machining
摘要
The paper presents a novel high-performance machining (HPM)–oriented asymmetric milling method. The basic connotation of the method is to realize high-precision and high-efficiency milling by utilizing the potential high-performance machining region (HPMR) of asymmetric flexible machining system. The causes and characteristics of the asymmetric flexibility in machining system are first clarified. Under the peripheral milling with curved tool path, one considers the non-parallel milling condition between the cutter and workpiece coordinate systems and time-varying feed direction, and the regenerative milling force model is derived based on the dynamic displacement coupling. The generalized milling dynamics model of asymmetric flexible machining system is established in the global coordinate system. The model has a better adaptability for complex milling conditions and lower modeling workload than the traditional ones. Then, the analysis shows that the milling dynamics of asymmetric flexible machining system has a significant feed direction–dependent characteristics and points out that the HPMR with higher stability and lower machining error would exist. This is not available in the symmetric flexible system and conventional modes. Based on this finding, a new method, namely, asymmetric milling, for HPM is proposed, and its specific process planning is given. The goal of the method is to actively control the feed direction angles and optimize the milling parameters, so as to enhance the machining efficiency without chatter and out of tolerance quality. Moreover, a series of experiments are carried out to verify the validity of the method. The results show that the proposed asymmetric milling method can improve the machining efficiency in both roughing and finishing operations.