abstract
- High-speed milling operations of thin walls are often limited by the so-called regenerative effect that causes poor surface finishing. To optimize the cutting process in terms of quality surface and productivity, the frequency response function (FRF) of the wall needs to be measured in order to identify the modal parameters of the system which are used to obtain the stability lobes that help identify the optimal system's parameter values to warrant stable cutting conditions. The aim of this work is to experimentally show the variation on the frequency response function (FRF) values obtained by using a laser Doppler vibrometer (LDV) device and accelerometer sensors during a milling operation processes of an aluminum thin-walled workpiece of 1 mm thick and 30 mm height. It is shown that the FRF values variations has strong influence on the stable cutting bounds. To further assess our findings, we used the collected experimental data obtained by using the LDV during milling machine cutting operation processes of several thin-walled workpieces to identify the cutting parameters values that allow us to obtain good quality and acceptable surface finish. © The Society for Experimental Mechanics 2014.