Relative Varying Dynamics Based Whole Cutting Process Optimization for Thin-walled Parts

Thin-walled parts are typically difficult-to-cut components due to the complex dynamics in cutting process. The dynamics is variant for part during machining, but invariant for machine tool. The variation of the relative dynamics results in the difference of cutting stage division and cutting parameter selection. This paper develops a novel method for whole cutting process optimization based on the relative varying dynamic characteristic of machining system. A new strategy to distinguish cutting stages depending on the dominated dynamics during machining process is proposed, and a thickness-dependent model to predict the dynamics of part is developed. Optimal cutting parameters change with stages, which can be divided by the critical thickness of part. Based on the dynamics comparison between machine tool and thickness-varying part, the critical thicknesses are predicted by an iterative algorithm. The proposed method is validated by the machining of three benchmarks. Good agreements have been obtained between prediction and experimental results in terms of stages identification, meanwhile, the optimized parameters perform well during the whole cutting process.

Automated summary

This paper presents a novel method for optimizing the whole cutting process based on the relative varying dynamic characteristic of the machining system. The method predicts the dynamics of the part and divides the cutting stages accordingly, allowing for optimal cutting parameter changes. An iterative algorithm is used to accurately predict the critical thickness. Experimental results demonstrate good agreement with the predicted results in terms of stage identification and performance of the optimized parameters throughout the cutting process.