Study of the dynamics of the face milling process, taking into account the torsional oscillations of the spindle
DOI:
https://doi.org/10.15276/opu.1.73.2026.05Keywords:
face milling, vibration resistance, torsional oscillations, trace regeneration, torsional rigidity of the drive, surface roughness, high-frequency vibrations, machine dynamicsAbstract
The article addresses the urgent problem of increasing vibration resistance in the face milling process and improving the quality of the processed surfaces of parts through parametric optimization of the torsional stiffness of the main drive elements. A comprehensive analysis of the dynamic interaction of the subsystems of the metal-cutting machine is carried out, and it is substantiated that the integration of tangential displacements of the spindle unit into the design schemes allows for the elimination of the limitations of classical linear models. A mathematical model of a closed dynamical system has been developed that accounts for fluctuations in the instrument’s angular velocity and the non-stationary nature of the delay time in the trace regeneration mechanism. Using a method from the theory of random processes, the influence of torsional variations on changes in the overlap coefficient and stability parameters is estimated. The theoretical conclusions were verified by an experimental study using a vertical milling machine, in which torsional stiffness decreased by varying the diameter of the intermediate shaft of the spindle head from 35 to 10 mm. It has been experimentally confirmed that at the level of torsional oscillations (with a change in rotational speed by 8% with a shaft diameter of 12 mm), the regenerative mechanism of auto-oscillations is destroyed. This leads to a 2.5-fold decrease in the amplitude of high-frequency linear vibrations of the machine carrier system and an improvement in the parameters of the surface microrelief, with a decrease in the roughness (Ra) from 2.3... 2.5 μm to 1.9 ... 2.0 μm. The limits of rational reduction of rigidity have been determined, beyond which excessive susceptibility of the drive begins to destabilize the process of molding. The scientific results substantiate the effectiveness of optimizing the dynamic characteristics of drives in increasing the integral vibration resistance of equipment.
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