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Five-axis flank milling of curved thin-walled parts: IPW dynamics extraction, multi-point contact modeling and 3D SLD prediction
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DOI：10.1016/j.cirpj.2026.05.007.png)
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Abstract
En 中文
For five-axis flank milling of curved thin-walled parts, accurate stability prediction requires the extraction of in-process workpiece (IPW) dynamic parameters along the tool path. This paper proposes an efficient IPW dynamics extraction method by integrating tool path information into the finite element meshing process. Cutter–workpiece contact points are embedded as mesh nodes within the material removal layer, enabling rapid extraction of multi-point and multi-modal dynamic parameters without node traversal and weighted interpolation. Based on the extracted dynamics, a time-varying multi-point contact dynamic model is established, and machining-position-dependent three-dimensional stability lobe diagrams (3D SLDs) are predicted. Quantitative results indicate that the required nodal computations for IPW dynamic parameter extraction are reduced by two orders of magnitude compared with those of conventional method. In addition, the proposed method well supports parallel computing, by which the prediction efficiency of 3D SLD can be increased by approximately 6 times compared to serial computing. Milling experiments on a thin-walled channel wall of a rotor hub in a gas wave refrigerator are conducted for different wall thicknesses and axial depths of cut. The predicted stability boundaries of the dynamic model show good agreement with the experimental results.
Keywords:
Five-axis flank milling
In-process workpiece dynamics
Multi-point contact modeling
Stability lobe diagrams
Finite element meshing
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5.4
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283
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