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Stability analysis of high speed milling process considering internal dam** of composite cutter bar and gyroscopic effect in rotating coordinates

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Abstract

Composite cutter bar with high dynamic stiffness and dam** can be used to suppress chatter in high speed milling process. However, for a rotating composite cutter bar, a new region of instability occurs at the high-speed range because of such factors as the internal dam** of the composite cutter bar and gyroscopic effect. This paper proposes a dynamic model of high speed milling system with composite cutter bar in fixed and rotating coordinate frame. Based on the viscoelastic constitutive relation of composite material, the dam** model is established by using the energy approach. The dynamic equations of the milling system are established according to Hamilton principle. The natural frequency and decay rate of composite cutter bar are studied by the proposed theory. The stability results are obtained by using the semi-discretization method and verified by the time domain response curves. The influences of gyroscopic effect, internal dam**, ply angle and aspect ratio are examined. It is shown that gyroscopic effect has a significant effect on stability lobe diagrams at the high speed range. A new unstable region appears at the high speed range when the internal dam** of the composite cutter bar is included.

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Acknowledgements

This work was supported by National Nature Science Foundation of China [Grant No. 52075305] and Shandong Province Higher Educational Science and Technology Program [Grant No. 2019KJB031]

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Authors and Affiliations

  1. Shandong University of Technology, Zibo, China

    Yuhuan Zhang & Leian Zhang

  2. Shandong Institute of Metrology, **an, China

    Zhongbin Feng

  3. Shandong Huiyu Auto Parts Co., Ltd, Binzhou, China

    Peiqiang Su

  4. Shandong University of Science and Technology, Qingdao, China

    Qiang Liu

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  1. Yuhuan Zhang
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  2. Zhongbin Feng
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  3. Leian Zhang
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  4. Peiqiang Su
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Contributions

All authors contributed to the study conception and design. Material preparation was performed by ZBF; data collection and analysis were performed by LAZ and PQ S. The first draft of the manuscript was written by YHZ, the simulation was performed by QL, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Leian Zhang.

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Zhang, Y., Feng, Z., Zhang, L. et al. Stability analysis of high speed milling process considering internal dam** of composite cutter bar and gyroscopic effect in rotating coordinates. Arch Appl Mech 94, 865–882 (2024). https://doi.org/10.1007/s00419-024-02552-2

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