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学者姓名:赵万华

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Systematic study of the prediction methods for machined surface topography and form error during milling process with flat-end cutter EI Scopus SCIE
期刊论文 | 2019 , 233 (1) , 226-242 | Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
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Abstract :

An enhanced time-domain simulation method of cutter/workpiece dynamic engagement during milling process is proposed in this article, which comprehensively considers the effect of multi-order modal characteristics of cutter system and cutter runout including offset and inclination. Based on the cutter dynamic displacement response, this article further presents the machined surface reconstruction algorithm and evaluation method for the form error. This research systematically studies and compares the calculation accuracy between the proposed method and other previous three kinds of methods. The effectiveness of the proposed method has been verified by a series of milling experiments successfully. By comparing with the other three methods, the proposed method shows a high calculation performance, especially under the milling condition with a large axial depth of cut and low damping or stiffness of cutter system. Besides, the results indicate that the form error has a strong dependence characteristic on the milling parameters, particularly on spindle speed. Additionally, cutter runout would easily cause over cut phenomenon on the machined surface and seriously deteriorate the surface roughness. © 2017, IMechE 2017.

Keyword :

Axial depth of cut Calculation accuracy Cutter runout Form errors Machined surface topography Milling process Modal characteristics Time-domain simulations

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GB/T 7714 Zhang, Xing , Zhang, Wei , Zhang, Jun et al. Systematic study of the prediction methods for machined surface topography and form error during milling process with flat-end cutter [J]. | Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture , 2019 , 233 (1) : 226-242 .
MLA Zhang, Xing et al. "Systematic study of the prediction methods for machined surface topography and form error during milling process with flat-end cutter" . | Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 233 . 1 (2019) : 226-242 .
APA Zhang, Xing , Zhang, Wei , Zhang, Jun , Pang, Bo , Zhao, Wanhua . Systematic study of the prediction methods for machined surface topography and form error during milling process with flat-end cutter . | Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture , 2019 , 233 (1) , 226-242 .
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A novel precision evaluation and analysis method for the direct driven high-speed feed system EI SCIE
期刊论文 | 2019 , 121 , 689-710 | Mechanical Systems and Signal Processing
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Abstract :

The direct driven feed system incorporates the merits of simple structure, high velocity and high acceleration, which has a bright future in the high-speed machine tools. However, because of the absence of the intermediate transmission components, there are different kinds of the disturbances which directly act on the mechanical system, leading to multiform motion errors. The complex motion errors in different motion processes will affect the final dynamic performance of the feed system with different forms and degrees, and finally affect the machining precision of the workpiece. It is of great significance to find a comprehensive and systematic precision evaluation method for the analysis and improvement of the dynamic precision of the feed system. In this paper, based on the motion characteristics and error sources, a novel precision evaluation and analysis method and indexes are proposed for the direct driven feed system. The electromechanical integrated model is established and then the dynamic precision in different motion processes with multi-source inputs are analytical presented. What is more, the experimental verification is carried out with different velocities. The results demonstrate that the proposed method can systematically evaluate the dynamic performance of direct drive high-speed feed system. Finally, the sensitive parameters of the precision evaluation indexes are discussed using the sensitivity analysis method (SAM), and the corresponding improvement measures are put forward. © 2018 Elsevier Ltd

Keyword :

Analytical presentation Dynamic precision Electromechanical integrated Experimental verification Feed systems High-speed machine tools Parameter sensitivity analysis Transmission components

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GB/T 7714 Yang, Xiaojun , Liu, Hui , Yang, Qingyu et al. A novel precision evaluation and analysis method for the direct driven high-speed feed system [J]. | Mechanical Systems and Signal Processing , 2019 , 121 : 689-710 .
MLA Yang, Xiaojun et al. "A novel precision evaluation and analysis method for the direct driven high-speed feed system" . | Mechanical Systems and Signal Processing 121 (2019) : 689-710 .
APA Yang, Xiaojun , Liu, Hui , Yang, Qingyu , Zhao, Wanhua . A novel precision evaluation and analysis method for the direct driven high-speed feed system . | Mechanical Systems and Signal Processing , 2019 , 121 , 689-710 .
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Interfacial effects on the dynamic stresses in high speed cutting of heterogeneous materials EI
会议论文 | 2018 , 77 , 151-154 | 8th CIRP Conference on High Performance Cutting, HPC 2018
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Abstract :

The microstructure of materials has an important effect on the chip formation and fracture process during metal cutting. Its heterogeneity makes the dynamic mechanical response of materials complicated, which would become more notable with the increase of cutting speed. In this paper, a spring-network discrete element model was established to characterize the heterogeneous material for cutting simulation. The dynamic stress propagation was investigated during the cutting tool impacting on the workpiece at high speeds. Voronoi tessellation method was utilized to create polycrystalline structures in the model and the stress distribution was discussed. Compared with the results by the homogeneous model, the distribution of dynamic stress in polycrystalline model is obviously discontinuous. Furthermore, the normal stress and shear stress propagates in the workpiece as longitudinal and transverse stress waves, which are reflected and transmitted at interfaces. The fluctuation of stress triaxiality is more obvious and changes significantly with the increase of cutting speed, which provides an idea for explaining the fracture mode transition of material in high speed cutting process. © 2018 The Authors. Published by Elsevier Ltd.

Keyword :

Discrete element modeling Dynamic mechanical response Fracture mode transitions Heterogeneous materials High speed cutting Polycrystalline models Polycrystalline structure Stress wave propagation

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GB/T 7714 He, Yong , Zhang, Jun , Jiang, Yifei et al. Interfacial effects on the dynamic stresses in high speed cutting of heterogeneous materials [C] . 2018 : 151-154 .
MLA He, Yong et al. "Interfacial effects on the dynamic stresses in high speed cutting of heterogeneous materials" . (2018) : 151-154 .
APA He, Yong , Zhang, Jun , Jiang, Yifei , Liu, Zhechao , Qi, Yutong , Zhao, Wanhua . Interfacial effects on the dynamic stresses in high speed cutting of heterogeneous materials . (2018) : 151-154 .
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Effect of morphological evolution of serrated chips on surface formation during high speed cutting Ti6Al4V EI
会议论文 | 2018 , 77 , 147-150 | 8th CIRP Conference on High Performance Cutting, HPC 2018
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Abstract :

Ti6Al4V alloys are widely used in aerospace industry due to its excellent mechanical properties, however, serrated chips are easily formed in high speed cutting and have great influence on the surface formation process. In this study, high speed cutting experiments and simulations ranging from 125-750m/min are conducted to explore the characteristics of serrated chips and surface quality. Accordingly, the evolution of serrated chips characteristics and its effect on cutting force and machined surface are discussed. The results show that the inhomogeneous plastic deformation of serrated chips directly causes the cutting forces fluctuation and then leads to the microwaves of machined surface. Furthermore, the surface toughness reaches the highest around 250 m/min and then decrease with the increase of cutting speed, meanwhile, as for the surface defect dimples, their shapes get equiaxed and sizes become small, which shows that the surface quality is improved by increasing the cutting speed. Therefore, surface quality could be controlled by optimizing cutting parameters with better understanding of the influence of chips evolution on machined surface quality. © 2018 The Authors. Published by Elsevier Ltd.

Keyword :

Cutting forces Cutting parameters High speed cutting Inhomogeneous plastic deformation Machined surface quality Morphological evolution Serrated chip Surface formation

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GB/T 7714 Xu, Xiang , Zhang, Jun , Liu, Hongguang et al. Effect of morphological evolution of serrated chips on surface formation during high speed cutting Ti6Al4V [C] . 2018 : 147-150 .
MLA Xu, Xiang et al. "Effect of morphological evolution of serrated chips on surface formation during high speed cutting Ti6Al4V" . (2018) : 147-150 .
APA Xu, Xiang , Zhang, Jun , Liu, Hongguang , Qi, Yutong , Liu, Zhechao , Zhao, Wanhua . Effect of morphological evolution of serrated chips on surface formation during high speed cutting Ti6Al4V . (2018) : 147-150 .
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Decoupling and effects of the mechanical vibration on the dynamic precision for the direct-driven machine tool EI SCIE Scopus
期刊论文 | 2018 , 95 (9-12) , 3243-3258 | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
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Abstract :

The linear motor feed system realizes direct drive, and all the intermediate transmission components are canceled. The thrust harmonics and other disturbances act on the mechanical system directly because the mover is connected with the driven parts, leading to obvious mechanical vibrations. The mechanical dynamic characteristics have important effects on the thrust characteristics and dynamic precision of linear motor feed system. In this paper, the decoupling and effects of the mechanical vibration on the dynamic precision for the direct driven are researched. Firstly, the mechanical kinetic model is established considering the characteristics of the joint between the guide rail and block and servo stiffness. Then the model realizes decoupling through the modal analysis, and the vibration responses in different directions are analytically calculated. What is more, a modeling method for the linear motor feed system considering the mechanical characteristic is put forward based on the modal separation method (MSM). The effects of the mechanical vibration on the dynamic precision of feed system are discussed. At last, the experiments are carried out and the influences of the structure parameters on the mechanical characteristics and displacement fluctuations are analyzed through sensitivity analysis, which provides a theoretical basis for the mechanical active design and improvement.

Keyword :

Dynamic precision Linear motor feed system Mechanical system Modal separation method Sensitivity analysis

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GB/T 7714 Yang, Xiaojun , Lu, Dun , Zhao, Wanhua . Decoupling and effects of the mechanical vibration on the dynamic precision for the direct-driven machine tool [J]. | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2018 , 95 (9-12) : 3243-3258 .
MLA Yang, Xiaojun et al. "Decoupling and effects of the mechanical vibration on the dynamic precision for the direct-driven machine tool" . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY 95 . 9-12 (2018) : 3243-3258 .
APA Yang, Xiaojun , Lu, Dun , Zhao, Wanhua . Decoupling and effects of the mechanical vibration on the dynamic precision for the direct-driven machine tool . | INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY , 2018 , 95 (9-12) , 3243-3258 .
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A non-contact calibration method for cutter runout with spindle speed dependent effect and analysis of its influence on milling process EI SCIE Scopus
期刊论文 | 2018 , 51 , 280-290 | PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
WoS CC Cited Count: 1 SCOPUS Cited Count: 1
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Abstract :

The Cutter runout in traditional studies about milling mechanics and dynamics are always assumed as a constant value. Actually, the dynamic characteristics and vibration response of spindle system will change under different spindle speeds, which would result in a spindle speed dependent effect for cutter runout. A non-contact calibration method for cutter runout with consideration of spindle speed dependent effect is proposed in the paper, and the influence of cutter runout on milling mechanics and dynamics is further analyzed. Based on the measured relative variation of tooth by the eddy current sensor measurement system, a numerical optimization method for identifying cutter runout parameters is presented. The main advantage of the method is simple and convenient, especially for studying the cutter runout under different spindle speeds. Then, the paper gives out an instantaneous uncut chip thickness model during cutter/workpiece engagement with runout effect, and puts forward an enhanced SDM for milling stability prediction. Theoretical and experimental results show that milling force, stability and SLE prediction considering the cutter runout with spindle speed dependent effect have a higher prediction accuracy compared with other previous methods. Lastly, the studies analyze the influence of cutter runout on milling force, milling stability and SLE, and the results indicate that cutter runout can improve the milling stability, but deteriorate the milling force excitation characteristics and SLE.

Keyword :

Calibration Cutter runout Milling force SLE Spindle speed dependent effect Stability

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GB/T 7714 Zhang, Xing , Zhang, Jun , Zhang, Wei et al. A non-contact calibration method for cutter runout with spindle speed dependent effect and analysis of its influence on milling process [J]. | PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY , 2018 , 51 : 280-290 .
MLA Zhang, Xing et al. "A non-contact calibration method for cutter runout with spindle speed dependent effect and analysis of its influence on milling process" . | PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY 51 (2018) : 280-290 .
APA Zhang, Xing , Zhang, Jun , Zhang, Wei , Li, Jianhui , Zhao, Wanhua . A non-contact calibration method for cutter runout with spindle speed dependent effect and analysis of its influence on milling process . | PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY , 2018 , 51 , 280-290 .
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Experimental study on fracture mechanism transformation in chip segmentation of Ti-6A1-4V alloys during high-speed machining EI SCIE Scopus
期刊论文 | 2018 , 257 , 132-140 | JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
WoS CC Cited Count: 1 SCOPUS Cited Count: 2
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Abstract :

Ti6AI4V alloy is one of the typically difficult-to-machine materials which is widely used in aerospace industry. During the machining process of Ti6A14V alloys, serrated chips are easily formed and would influence cutting forces significantly. In this study, the variation of cutting forces of Ti-6A1-4V alloys during high-speed milling from 50-500 m/min is investigated, and the fracture mechanisms and microstructure evolution of chips are analyzed by optical microscope (OM), scan electron microscope (SEM) and transmission electron microscope (TEM). The results show that cutting forces and serrated degree of chips both increase first and then decrease with the increase of cutting speeds, especially when adiabatic shear bands appear. The microstructure evolution inside adiabatic shear bands also show a significant difference with different chip morphology at different cutting speeds, which finally cause the variation of cutting forces due to the change of fracture mechanisms between chip segmentations. As a result, the evolution of adiabatic shear bands is analyzed, and replica method by polydimethylsiloxane (PDMS) is used to reveal the relationship between cutting forces variation and fracture mechanism transformation in chip segmentation. It shows the relationship between cutting forces and microstructure evolution in adiabatic shear bands, and the transformation of fracture mechanism between type-I and type-II would occur around the gap between chip segmentations, where cutting forces are higher under type-I fracture.

Keyword :

Titanium alloys Microstructure evolution Fracture mechanism Chip segmentation High speed machining

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GB/T 7714 Liu, Hongguang , Zhang, Jun , Xu, Xiang et al. Experimental study on fracture mechanism transformation in chip segmentation of Ti-6A1-4V alloys during high-speed machining [J]. | JOURNAL OF MATERIALS PROCESSING TECHNOLOGY , 2018 , 257 : 132-140 .
MLA Liu, Hongguang et al. "Experimental study on fracture mechanism transformation in chip segmentation of Ti-6A1-4V alloys during high-speed machining" . | JOURNAL OF MATERIALS PROCESSING TECHNOLOGY 257 (2018) : 132-140 .
APA Liu, Hongguang , Zhang, Jun , Xu, Xiang , Zhao, Wanhua . Experimental study on fracture mechanism transformation in chip segmentation of Ti-6A1-4V alloys during high-speed machining . | JOURNAL OF MATERIALS PROCESSING TECHNOLOGY , 2018 , 257 , 132-140 .
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Integrated modeling and analysis of ball screw feed system and milling process with consideration of multi-excitation effect EI SCIE Scopus
期刊论文 | 2018 , 98 , 484-505 | MECHANICAL SYSTEMS AND SIGNAL PROCESSING
WoS CC Cited Count: 3 SCOPUS Cited Count: 3
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Abstract :

The present researches about feed drive system and milling process are almost independent with each other, and ignore the interaction between the two parts, especially the influence of nonideal motion of feed drive system on milling process. An integrated modeling method of ball screw feed system and milling process with multi-excitation effect is proposed in this paper. In the integrated model, firstly an analytical model of motor harmonic torque with consideration of asymmetrical drive circuit and asymmetrical permanent magnet is given. Then, the numerical simulation procedure of cutter/workpiece engagement during milling process with displacement fluctuation induced by harmonic torque is put forward, which is followed by the solving flow for the proposed integrated model. Based on the integrated model, a new kind of quality defect shown as contour low frequency oscillation on machined surface is studied by experiments and simulations. The results demonstrate that the forming mechanism of the contour oscillation can be ascribed to the multi-excitation effect with motor harmonic torque and milling force. Moreover, the influence of different milling conditions on the contour oscillation characteristics, particularly on surface roughness, are further discussed. The results indicate that it is necessary to explain the cause of the new kind of quality defect with a view of system integration. (C) 2017 Elsevier Ltd. All rights reserved.

Keyword :

Ball screw feed system Integrated modeling Low frequency oscillation Milling process Multi-excitation effect Roughness

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GB/T 7714 Zhang, Xing , Zhang, Jun , Zhang, Wei et al. Integrated modeling and analysis of ball screw feed system and milling process with consideration of multi-excitation effect [J]. | MECHANICAL SYSTEMS AND SIGNAL PROCESSING , 2018 , 98 : 484-505 .
MLA Zhang, Xing et al. "Integrated modeling and analysis of ball screw feed system and milling process with consideration of multi-excitation effect" . | MECHANICAL SYSTEMS AND SIGNAL PROCESSING 98 (2018) : 484-505 .
APA Zhang, Xing , Zhang, Jun , Zhang, Wei , Liang, Tao , Liu, Hui , Zhao, Wanhua . Integrated modeling and analysis of ball screw feed system and milling process with consideration of multi-excitation effect . | MECHANICAL SYSTEMS AND SIGNAL PROCESSING , 2018 , 98 , 484-505 .
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Coupled Model of Rotary-Tilting Spindle Head for Pose-Dependent Prediction of Dynamics EI SCIE Scopus
期刊论文 | 2018 , 140 (8) | JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
WoS CC Cited Count: 1 SCOPUS Cited Count: 1
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Abstract :

Five-axis machine with rotary-tilting spindle head (RTSH) is always used for sculptured surface machining, and the tool-tip dynamics in various machining postures along the tool path directly affect the machining accuracy and stability. To rapidly evaluate the tool-tip dynamics at different postures during the structural design of tool-spindle-spindle head (TSSH) assembly, this paper proposes a coupled dynamic model of tool-spindle-bearing system (TSBS) and RTSH. The model is a rigid-flexible multibody dynamic model with 36 degrees-of-freedom (DOFs), where in the rotary shaft, swivel shaft and housing are treated as rigid bodies; the tool, tool holder, and spindle shaft are modeled by reduced beams; the bearings and flexible joints are modeled as spring-damping elements. The fully Cartesian coordinates and Lagrangian method are employed to deduce a general parametric dynamic equation. The analytical method for calculating the contact stiffness of bearings and flexible joints is systematically presented, including tool-holder joint, holder-spindle joint, spindle bearings, hirth coupling, and the bearings and locking joints of rotary and swivel shafts. The model is verified by the frequency response functions (FRFs) testing and modal testing at different postures. The experimental results show that the proposed model can be used for accurate and efficient evaluation of the tool-tip FRFs, natural frequencies and mode shapes of TSSH at an arbitrary posture.

Keyword :

tool-holder-spindle rotary-tilting spindle head joint stiffness coupled dynamic model pose-dependent dynamics

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GB/T 7714 Du, Chao , Zhang, Jun , Lu, Dun et al. Coupled Model of Rotary-Tilting Spindle Head for Pose-Dependent Prediction of Dynamics [J]. | JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME , 2018 , 140 (8) .
MLA Du, Chao et al. "Coupled Model of Rotary-Tilting Spindle Head for Pose-Dependent Prediction of Dynamics" . | JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME 140 . 8 (2018) .
APA Du, Chao , Zhang, Jun , Lu, Dun , Zhang, Huijie , Zhao, Wanhua . Coupled Model of Rotary-Tilting Spindle Head for Pose-Dependent Prediction of Dynamics . | JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME , 2018 , 140 (8) .
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A parametric modeling method for the pose-dependent dynamics of bi-rotary milling head EI SCIE Scopus
期刊论文 | 2018 , 232 (5) , 797-815 | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
WoS CC Cited Count: 2 SCOPUS Cited Count: 6
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Abstract :

Bi-rotary milling head is one of the core components of five-axis machining center, and its dynamic characteristics directly affect the machining stability and accuracy. During the sculptured surface machining, the bi-rotary milling head exhibits varying dynamics in various machining postures. To facilitate rapid evaluation of the dynamic behavior of the bi-rotary milling head within the whole workspace, this article presents a method for parametrically establishing dynamic equation at different postures. The rotating and swing shafts are treated as rigid bodies. The varying stiffness of the flexible joints (such as bearings and hirth coupling) affected by gravity and cutting force at different swing angles is analyzed and then a multi-rigid-body dynamic model of the bi-rotary milling head considering the pose-varying joint stiffness is established. The Lagrangian method is employed to deduce the parametric dynamic equation with posture parameters. The static stiffness, natural frequencies and frequency response functions at different postures are simulated using the parametric equation and verified by the impact testing experiments. The theoretical and experimental results show that the dynamics of the bi-rotary milling head vary with the machining postures, and the proposed method can be used for efficient and accurate evaluation of the pose-dependent dynamics at the design stage.

Keyword :

Bi-rotary milling head dynamic model joint stiffness parametric modeling method pose-dependent dynamics

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GB/T 7714 Du, Chao , Zhang, Jun , Lu, Dun et al. A parametric modeling method for the pose-dependent dynamics of bi-rotary milling head [J]. | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE , 2018 , 232 (5) : 797-815 .
MLA Du, Chao et al. "A parametric modeling method for the pose-dependent dynamics of bi-rotary milling head" . | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE 232 . 5 (2018) : 797-815 .
APA Du, Chao , Zhang, Jun , Lu, Dun , Zhang, Huijie , Zhao, Wanhua . A parametric modeling method for the pose-dependent dynamics of bi-rotary milling head . | PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE , 2018 , 232 (5) , 797-815 .
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