An integrated approach for the predictions of the workpiece vibrations during machining of aerospace structure-numerical and experimental validation

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Proceedings titleASME International Mechanical Engineering Congress and Exposition, Proceedings (IMECE)
ConferenceASME 2012 International Mechanical Engineering Congress and Exposition, IMECE 2012, 9 November 2012 through 15 November 2012, Houston, TX
IssuePARTS A, B and C
Pages20672076; # of pages: 10
SubjectAccurate measurement; Aerospace structural components; Design and optimization; Experimental validations; High speed machining; Holonomic constraints; Semi-analytical model; Thin walled components; Dynamic models; Fixtures (tooling); Forecasting; Integrated control; Thin walled structures; Machining
AbstractAccurate predictions of the workpiece vibrations during high speed machining of aerospace structural components is a critical issue since it affects the accuracy of the final part. For fixture design purposes, and for force predictions, the computational efficiency of the dynamic models predicting the workpiece vibrations is a crucial factor since it affects the cycle time for the design and optimization of the fixtures. Most of the available dynamic models are based on computationally prohibitive techniques, such as finite element analysis. In this work, an integrated approach, based on recently developed semi-analytical models, is presented for the analysis of the effect of the fixture layout on the dynamics of thin-walled structures while taking into account the continuous change of thickness of the workpiece, and the effect of rigid and deformable fixture supports. The developed approach is based on plate models with holonomic constraints and finite stiffness springs. This approach, together with all the developed models and formulations are validated numerically for different workpiece geometries and various types of loading. An experimental study has been performed to validate this approach through the machining of thin-walled components. It was found that this approach led to prediction errors within 10% and more than 20 times reduction in the computation time. The challenge of filtering the effect of the dynamics of the force measurement system from the measured signals was overcome by developing a new hybrid semi-analytical methodology for accurate measurement of the machining forces. Copyright © 2012 by ASME.
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AffiliationNational Research Council Canada (NRC-CNRC); Aerospace (AERO-AERO)
Peer reviewedYes
NPARC number21269242
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Record identifier3a8d8fb5-6c00-4276-9a81-f5ef210a803b
Record created2013-12-12
Record modified2016-05-09
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