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Milling Force Model for Aviation Aluminum Alloy: Academic Insight and Perspective Analysis 被引量:13
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作者 Zhenjing Duan Changhe Li +13 位作者 Wenfeng Ding Yanbin Zhang Min Yang Teng Gao Huajun Cao Xuefeng Xu Dazhong Wang Cong Mao Hao Nan Li Gupta Munish Kumar Zafar Said Sujan Debnath Muhammad Jamil Hafiz Muhammad Ali 《Chinese Journal of Mechanical Engineering》 SCIE EI CAS CSCD 2021年第1期54-88,共35页
Aluminum alloy is the main structural material of aircraft,launch vehicle,spaceship,and space station and is processed by milling.However,tool wear and vibration are the bottlenecks in the milling process of aviation ... Aluminum alloy is the main structural material of aircraft,launch vehicle,spaceship,and space station and is processed by milling.However,tool wear and vibration are the bottlenecks in the milling process of aviation aluminum alloy.The machining accuracy and surface quality of aluminum alloy milling depend on the cutting parameters,material mechanical properties,machine tools,and other parameters.In particular,milling force is the crucial factor to determine material removal and workpiece surface integrity.However,establishing the prediction model of milling force is important and difficult because milling force is the result of multiparameter coupling of process system.The research progress of cutting force model is reviewed from three modeling methods:empirical model,finite element simulation,and instantaneous milling force model.The problems of cutting force modeling are also determined.In view of these problems,the future work direction is proposed in the following four aspects:(1)high-speed milling is adopted for the thin-walled structure of large aviation with large cutting depth,which easily produces high residual stress.The residual stress should be analyzed under this particular condition.(2)Multiple factors(e.g.,eccentric swing milling parameters,lubrication conditions,tools,tool and workpiece deformation,and size effect)should be considered comprehensively when modeling instantaneous milling forces,especially for micro milling and complex surface machining.(3)The database of milling force model,including the corresponding workpiece materials,working condition,cutting tools(geometric figures and coatings),and other parameters,should be established.(4)The effect of chatter on the prediction accuracy of milling force cannot be ignored in thin-walled workpiece milling.(5)The cutting force of aviation aluminum alloy milling under the condition of minimum quantity lubrication(mql)and nanofluid mql should be predicted. 展开更多
关键词 milling Aluminum alloy force model Empirical model Finite element model Instantaneous milling force model
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3D FEM Simulation of Milling Force in Corner Machining Process 被引量:2
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作者 Caixu YUE Cui HUANG +2 位作者 Xianli LIU Shengyu HAO Jun LIU 《Chinese Journal of Mechanical Engineering》 SCIE EI CAS CSCD 2017年第2期286-293,共8页
To optimize milling force and machining accuracy quality in corner milling process, the changing law of milling force is revealed by Finite Element Method(FEM). Based on DEFORM software a serial of 3D FEM models for... To optimize milling force and machining accuracy quality in corner milling process, the changing law of milling force is revealed by Finite Element Method(FEM). Based on DEFORM software a serial of 3D FEM models for corner milling process are devloped. Tool curved trajectory is achieved by establishing accurate relationship of tool location with milling time. Adaptive remeshing technique and iterative algorithm are adopted to ensure convergence of FEM model. Component force characteristics are revealed by analyzing FEM simulation results. It indicates that the milling force in Y direction becomes negative comparing with forces in X and Z direction. Magnitude of forces in three directions decreases with increase of spindle speed, while it increases with increase of milling feedrate. The simulation results for cutting force are in good agreement with those obtained from experiment. The FEM simulation model is first successfully established for corner milling process in this study, and the results provide a guide for optimizing cutting parameters in cutting process. 展开更多
关键词 FEM simulation Corner milling Hardened steel milling force
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Research on milling force in precision milling SiC_p/Al composite materials 被引量:2
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作者 王洪祥 杨嘉 +1 位作者 刘占山 翟文杰 《Journal of Harbin Institute of Technology(New Series)》 EI CAS 2012年第5期1-5,共5页
The experiment of PCD cutter and YG6X cutter milling SiCp/Al matrix composites was conducted, and the effect of tool material and machining parameters on cutting force and surface roughness was investigated, and the m... The experiment of PCD cutter and YG6X cutter milling SiCp/Al matrix composites was conducted, and the effect of tool material and machining parameters on cutting force and surface roughness was investigated, and the milling process of PCD tool was simulated with finite element software. The results showed that the axial thrust force was larger than the other two while precision milling 45% volume SiCp/Al matrix composites by YG6X tool, which resulting from great compressive strength of the material. The cutting force of PCD tool was much smaller than that of the YG6X, and the surface roughness of PCD tool was also smaller. Considering the cutting force and machining surface quality, YG6X should be used for rough machining, and PCD should be used for precision machining. The results of finite element simulation of PCD tools were in good agreement with experimental results, which can provide basis for production. 展开更多
关键词 SICP/AL milling force ROUGHNESS
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Experiment and finite element analysis of micromilling force
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作者 孙雅洲 孟庆鑫 《Journal of Harbin Institute of Technology(New Series)》 EI CAS 2008年第5期648-652,共5页
For predicting the milling force in process of micromilling aluminum alloy, the law for micromilling force changing under different milling parameters was studied. The elastic-plastic finite elelent model of micromill... For predicting the milling force in process of micromilling aluminum alloy, the law for micromilling force changing under different milling parameters was studied. The elastic-plastic finite elelent model of micromilling was found using general commercial software. During modeling, the Johnson-Cook' s coupled thermal- mechanical model was used as workpieee material model, the Johnson-Cook' s shear failure principle was adopted as workpiece failure principle, and the coupled thermal-mechanical hexahedron strain hybrid modules and serf-adaptive grid technology based on the updated Lagrange formulation were used to mesh the workpiece' s elements, while the friction between tool and workpiece obeys the modified Coulomb' s law that combines with the sliding friction and the adhesive friction. By means of finite element analysis, the law for micromilling force changing under different milling parameters was obtained, and the results were analyzed and compared. Finally micromilling experiments were carried out to validate the results of simulation. 展开更多
关键词 MICROmilling milling force milling parameter finite element method
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Study on the Predictive of Dynamic Milling Force of Milling Process Based on Data Mining
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作者 JIN Lan WU Lishuang +1 位作者 ZHANG Xuefeng XIE Liming 《Wuhan University Journal of Natural Sciences》 CAS CSCD 2022年第5期439-452,共14页
To improve surface accuracy of the work-piece and obtain potentially valuable information,a dynamic milling force prediction model was proposed based on data mining.In view of the current dynamic milling force obtaine... To improve surface accuracy of the work-piece and obtain potentially valuable information,a dynamic milling force prediction model was proposed based on data mining.In view of the current dynamic milling force obtained through finite element simulation and analytical calculation,in the finite element modeling,the model built is inevitably different from the actual working conditions,and the analytical calculation is slightly cumbersome and complex,and a dynamic milling force prediction model based on data mining is proposed.The model was established using a combination of regression analysis and Radial Basis Function(RBF) neural network.Using data mining as a means,the internal relationship between milling force,cutting parameters,temperature,vibration and surface quality is deeply analyzed,and the influence of dynamic milling force changes on different situations is extracted and summarized by the methods of cluster analysis and correlation analysis.The results show that the proposed dynamic milling force model has a good prediction effect,ensures the production quality,reduces the occurrence of flutter,improves the surface accuracy of the work-piece,and provides a more accurate basis for the selection of process parameters. 展开更多
关键词 data mining data modeling dynamic milling force prediction of milling force
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A cortical bone milling force model based on orthogonal cutting distribution method 被引量:6
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作者 Qi-Sen Chen Li Dai +1 位作者 Yu Liu Qiu-Xiang Shi 《Advances in Manufacturing》 SCIE CAS CSCD 2020年第2期204-215,共12页
In orthopedic surgery,the bone milling force has attracted attention owing to its significant influence on bone cracks and the breaking of tools.It is necessary to build a milling force model to improve the process of... In orthopedic surgery,the bone milling force has attracted attention owing to its significant influence on bone cracks and the breaking of tools.It is necessary to build a milling force model to improve the process of bone milling.This paper proposes a cortical bone milling force model based on the orthogonal cutting distribution method(OCDM),explaining the effect of anisotropic bone materials on milling force.According to the model,the bone milling force could be represented by the equivalent effect of a transient cutting force in a rotating period,and the transient milling force could be calculated by the transient milling force coefficients,cutting thickness,and cutting width.Based on the OCDM,the change in transient cutting force coefficients during slotting can be described by using a quadratic polynomial.Subsequently,the force model is updated for robotic bone milling,considering the low stiffness of the robot arm.Next,an experimental platform for robotic bone milling is built to simulate the milling process in clinical operation,and the machining signal is employed to calculate the milling force.Finally,according to the experimental result,the rationality of the force model is verified by the contrast between the measured and predicted forces.The milling force model can satisfy the accuracy requirement for predicting the milling force in the different processing directions,and it could promote the development of force control in orthopedic surgery. 展开更多
关键词 Robotic milling force Cortical bone Cutting force coefficient Orthogonal cutting distribution
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Experimental Study on Titanium Alloy Cutting Property and Wear Mechanism with Circular-arc Milling Cutters 被引量:3
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作者 Tao Chen Jiaqiang Liu +3 位作者 Gang Liu Hui Xiao Chunhui Li Xianli Liu 《Chinese Journal of Mechanical Engineering》 SCIE EI CAS CSCD 2023年第3期219-229,共11页
Titanium alloy has been applied in the field of aerospace manufacturing for its high specific strength and hardness.Nonetheless,these properties also cause general problems in the machining,such as processing ineffici... Titanium alloy has been applied in the field of aerospace manufacturing for its high specific strength and hardness.Nonetheless,these properties also cause general problems in the machining,such as processing inefficiency,serious wear,poor workpiece face quality,etc.Aiming at the above problems,this paper carried out a comparative experimental study on titanium alloy milling based on the CAMCand BEMC.The variation law of cutting force and wear morphology of the two tools were obtained,and the wear mechanism and the effect of wear on machining quality were analyzed.The conclusion is that in contrast with BEMC,under the action of cutting thickness thinning mechanism,the force of CAMC was less,and its fluctuation was more stable.The flank wear was uniform and near the cutting edge,and the wear rate was slower.In the early period,the wear mechanism of CAMC was mainly adhesion.Gradually,oxidative wear also occurred with milling.Furthermore,the surface residual height of CAMC was lower.There is no obvious peak and trough accompanied by fewer surface defects. 展开更多
关键词 Circular-arc milling cutter Titanium alloy Ball-end milling cutter Surface quality milling force Tool wear Machining quality
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Cutting Characteristics of Force Controllable Milling Head
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作者 Shirakashi Takahiro Shibuya Wataru 《厦门大学学报(自然科学版)》 CAS CSCD 北大核心 2002年第S1期108-,共1页
In order to control cutting force and its direction i n milling operation, a new milling head was developed. The head has two milling cutters, which are connected by a pair of gears and rotate in opposite direction re... In order to control cutting force and its direction i n milling operation, a new milling head was developed. The head has two milling cutters, which are connected by a pair of gears and rotate in opposite direction respectively. Both up-cut and down-cut can be carried out simultaneously by t hese milling cutters. The each depth of cut, the ratio of up/down cutting depth , by these cutters can be also selected. The cutting force characteristics were experimentally discussed by changing the ratio. The cutting force and its locus can be also changed by the selection of the ratio of up/down cutting depth. For practical usage of the head the analytical prediction method of the cutting forc e characteristics under selected cutting condition was proposed based on the ene rgy approach method proposed, in which both of cutting force characteristics of a single milling cutter and the combined milling cutter under a selected up/dow n cutting depth ratio were analytically estimated based on the two dimensional c utting data. It was experimentally shown that in NC milling machine the cutting force locus was controlled in pre-determined direction under various tool paths . 展开更多
关键词 Cutting Characteristics of force Controllable milling Head
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Force model in electrostatic atomization minimum quantity lubrication milling GH4169 and performance evaluation
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作者 Min YANG Hao MA +7 位作者 Zhonghao LI Jiachao HAO Mingzheng LIU Xin CUI Yanbin ZHANG Zongming ZHOU Yunze LONG Changhe LI 《Frontiers of Mechanical Engineering》 SCIE CSCD 2024年第4期55-72,共18页
The nickel-based high-temperature alloy GH4169 is the material of choice for manufacturing critical components in aeroengines,and electrostatic atomization minimum quantity lubrication(EMQL)milling represents a fundam... The nickel-based high-temperature alloy GH4169 is the material of choice for manufacturing critical components in aeroengines,and electrostatic atomization minimum quantity lubrication(EMQL)milling represents a fundamental machining process for GH4169.However,the effects of electric field parameters,jet parameters,nozzle position,and milling parameters on milling performance remain unclear,which constrains the broad application of EMQL in aerospace manufacturing.This study evaluated the milling performance of EMQL on nickel-based alloys using soybean oil as the lubrication medium.Results revealed that compared with conventional pneumatic atomization MQL milling,EMQL reduced the milling force by 15.2%-15.9%,lowered the surface roughness by 30.9%-54.2%,decreased the average roughness spacing by 47.4%-58.3%,and decreased the coefficient of friction and the specific energy of cutting by 55%and 19.6%,respectively.Subsequent optimization experiments using orthogonal arrays demonstrated that air pressure most significantly affected the milling force and specific energy of cutting,with a contribution rate of 22%,whereas voltage had the greatest effect on workpiece surface roughness,contributing 36.71%.Considering the workpiece surface morphology and the potential impact of droplet drift on environmental and health safety,the optimal parameter combination identified were a flow rate of 80 mL/h,an air pressure of 0.1 MPa,a voltage of 30 kV,a nozzle incidence angle of 35°,an elevation angle of 30°,and a target distance of 40 mm.This research aimed to provide technical insights for improving the surface integrity of aerospace materials that are difficult to machine during cutting operations. 展开更多
关键词 electrostatic atomization MQL nickel-based alloys milling force surface roughness force model
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A model of deformation of thin-wall surface parts during milling machining process 被引量:11
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作者 王凌云 黄红辉 +2 位作者 Rae W.WEST 李厚佳 杜继涛 《Journal of Central South University》 SCIE EI CAS CSCD 2018年第5期1107-1115,共9页
A three-dimensional finite element model was established for the milling of thin-walled parts. The physical model of the milling of the part was established using the AdvantEdge FEM software as the platform. The alumi... A three-dimensional finite element model was established for the milling of thin-walled parts. The physical model of the milling of the part was established using the AdvantEdge FEM software as the platform. The aluminum alloy impeller was designated as the object to be processed and the boundary conditions which met the actual machining were set. Through the solution, the physical quantities such as the three-way cutting force, the tool temperature, and the tool stress were obtained, and the calculation of the elastic deformation of the thin-walled blade of the free-form surface at the contact points between the tool and the workpiece was realized. The elastic deformation law of the thin-walled blade was then predicted. The results show that the maximum deviation between the predicted value and the actual measured machining value of the elastic deformation was 26.055 μm; the minimum deviation was 2.011 μm, with the average deviation being 10.154 μm. This shows that the prediction is in close agreement with the actual result. 展开更多
关键词 thin-walled surface parts milling force elastic deformation finite element model
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A New Dynamics Analysis Model for Five-Axis Machining of Curved Surface Based on Dimension Reduction and Mapping
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作者 Minglong Guo Zhaocheng Wei +2 位作者 Minjie Wang Zhiwei Zhao Shengxian Liu 《Chinese Journal of Mechanical Engineering》 SCIE EI CAS CSCD 2023年第6期172-184,共13页
The equipment used in various fields contains an increasing number of parts with curved surfaces of increasing size.Five-axis computer numerical control(CNC)milling is the main parts machining method,while dynamics an... The equipment used in various fields contains an increasing number of parts with curved surfaces of increasing size.Five-axis computer numerical control(CNC)milling is the main parts machining method,while dynamics analysis has always been a research hotspot.The cutting conditions determined by the cutter axis,tool path,and workpiece geometry are complex and changeable,which has made dynamics research a major challenge.For this reason,this paper introduces the innovative idea of applying dimension reduction and mapping to the five-axis machining of curved surfaces,and proposes an efficient dynamics analysis model.To simplify the research object,the cutter position points along the tool path were discretized into inclined plane five-axis machining.The cutter dip angle and feed deflection angle were used to define the spatial position relationship in five-axis machining.These were then taken as the new base variables to construct an abstract two-dimensional space and establish the mapping relationship between the cutter position point and space point sets to further simplify the dimensions of the research object.Based on the in-cut cutting edge solved by the space limitation method,the dynamics of the inclined plane five-axis machining unit were studied,and the results were uniformly stored in the abstract space to produce a database.Finally,the prediction of the milling force and vibration state along the tool path became a data extraction process that significantly improved efficiency.Two experiments were also conducted which proved the accuracy and efficiency of the proposed dynamics analysis model.This study has great potential for the online synchronization of intelligent machining of large surfaces. 展开更多
关键词 Curved surface Five-axis machining Dimension reduction and mapping milling force DYNAMICS
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Theoretical and Experimental Analysis on Influence of Revolution Radius in Orbital Drilling 被引量:1
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作者 杨吟飞 单以才 +2 位作者 章婷 何宁 李亮 《Transactions of Nanjing University of Aeronautics and Astronautics》 EI 2014年第5期498-507,共10页
Revolution radius is one of the significant parameters in orbital drilling,which has great influence on many factors,such as the cutting area of front and side cutting edge,undeformed chip geometry,delamination and bu... Revolution radius is one of the significant parameters in orbital drilling,which has great influence on many factors,such as the cutting area of front and side cutting edge,undeformed chip geometry,delamination and burr at hole exit side,hole surface roughness,cutting tool force and deflection,chip removal and heat transmission.First,the influence of revolution radius on the factors is discussed theoretically in detail.Analysis results show that big revolution radius can reduce axial cutting force,restrain exit delamination and burr,and improve chip removal and heat transmission.Then,single factor test and orthogonal test are utilized in the two processing methods as machining unidiameter holes with several cutting tools and machining different diameter holes with one tool.Finally,the influence of revolution radius on cutting force and hole machining precision is studied.These results provide a profound foundation for future optimization of cutting control parameters. 展开更多
关键词 robotic hole-making system orbital drilling revolution radius milling forces hole quality
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Engagement Angle Modeling for Multiple-circle Continuous Machining and Its Application in the Pocket Machining 被引量:1
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作者 Shixiong WU Wei MA +2 位作者 Haiping BAI Chengyong WANG Yuexian SONG 《Chinese Journal of Mechanical Engineering》 SCIE EI CAS CSCD 2017年第2期256-271,共16页
The progressive cutting based on auxiliary paths is an effective machining method for the material accumulating region inside the mould pocket. But the method is commonly based on the radial depth of cut as the contro... The progressive cutting based on auxiliary paths is an effective machining method for the material accumulating region inside the mould pocket. But the method is commonly based on the radial depth of cut as the control parameter, further more there is no more appropriate adjustment and control approach. The end-users often fall to set the parameter correctly, which leads to excessive tool load in the process of actual machining. In order to make more reasonable control of the machining load and toolpath, an engagement angle modeling method for multiplecircle continuous machining is presented. The distribution mode of multiple circles, dynamic changing process of engagement angle, extreme and average value of engage- ment angle are carefully considered. Based on the engagement angle model, numerous application techniques for mould pocket machining are presented, involving the calculation of the milling force in multiple-circle continuous machining, and rough and finish machining path planning and load control for the material accumulating region inside the pocket, and other aspects. Simulation and actual machining experiments show that the engagement angle modeling method for multiple-circle continuous machining is correct and reliable, and the related numerous application techniques for pocket machining are feasible and effective. The proposed research contributes to the analysis and control tool load effectively and tool-path planning reasonably for the material accumulating region inside the mould pocket. 展开更多
关键词 Pocket · Engagement angle · milling force Circle · High·speed machining
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Cutting force prediction for circular end milling process 被引量:17
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作者 Wu Baohai Yan Xue +1 位作者 Luo Ming Gao Ge 《Chinese Journal of Aeronautics》 SCIE EI CAS CSCD 2013年第4期1057-1063,共7页
A deduced cutting force prediction model for circular end milling process is presented in this paper. Traditional researches on cutting force model usually focus on linear milling process which does not meet other cut... A deduced cutting force prediction model for circular end milling process is presented in this paper. Traditional researches on cutting force model usually focus on linear milling process which does not meet other cutting conditions, especially for circular milling process. This paper presents an improved cutting force model for circular end milling process based on the typical linear milling force model. The curvature effects of tool path on chip thickness as well as entry and exit angles are analyzed, and the cutting force model of linear milling process is then corrected to fit circular end milling processes. Instantaneous cutting forces during circular end milling process are predicted according to the proposed model. The deduced cutting force model can be used for both linear and circular end milling processes. Finally, circular end milling experiments with constant and variable radial depth were carried out to verify the availability of the proposed method. Experiment results show that measured results and simulated results corresponds well with each other. 展开更多
关键词 Chip thickness Circular end milling Cutting force Machining Radial depth Tool path curvature
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Milling surface roughness for 7050 aluminum alloy cavity influenced by nozzle position of nanofluid minimum quantity lubrication 被引量:17
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作者 Zhenjing DUAN Changhe LI +7 位作者 Yanbin ZHANG Lan DONG Xiufang BAI Min YANG Dongzhou JIA Runze LI Huajun CAO Xuefeng XU 《Chinese Journal of Aeronautics》 SCIE EI CAS CSCD 2021年第6期33-53,共21页
In nanofluid minimum quantity lubrication(NMQL)milling of aviation aluminum alloy,it is the bottleneck problem to adjust the position parameters(target distance,incidence angle,and elevation angle)of the nozzle to imp... In nanofluid minimum quantity lubrication(NMQL)milling of aviation aluminum alloy,it is the bottleneck problem to adjust the position parameters(target distance,incidence angle,and elevation angle)of the nozzle to improve the surface roughness of milling,which has large and uncontrollable errors.In this paper,the influence law of milling cutter speed,helical angle,and cavity shape on the flow field around the milling cutter was studied,and the optimal nozzle profile parameters were obtained.Using 7050 aluminum alloy as the workpiece material,the milling experiment of the NMQL cavity was conducted by utilizing cottonseed oil-based Al2 O3 nanofluid.Results show that the high velocity of the surrounding air flow field and the strong gas barrier could be attributed to high rotating velocities of the milling cutter.The incidence angle of the nozzle was consistent with the helical angle of the milling cutter,the target distance was appropriate at 25–30 mm,and the elevation angle was suitable at 60°–65°.The range and variance analyses of the signal-to-noise ratio of milling force and roughness were performed,and the chip morphology was observed and analyzed.The results show that the optimal combination of nozzle position parameters was the target distance of 30 mm,the incidence angle of 35°,and the elevation angle of 60°.Among these parameters,target distance had the largest impact on cutting performance with a contribution rate of more than 55%,followed by incidence angle and elevation contribution rate.Analysis by orthogonal experiment revealed that the nozzle position parameters were appropriate,and Ra(0.087 lm)was reduced by 30.4%from the maximum value(0.125 lm).Moreover,Rsm(0.05 mm)was minimum,which was 36%lower than that of the seventh group(Rsm=0.078 mm). 展开更多
关键词 7050 aluminum alloy milling milling force Nanofluid minimum quantity lubrication Nozzle position Orthogonal experimental ROUGHNESS SNR
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Chatter identification of thin-walled parts for intelligent manufacturing based on multi-signal processing 被引量:4
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作者 Dong-Dong Li Wei-Min Zhang +2 位作者 Yuan-Shi Li Feng Xue Jürgen Fleischer 《Advances in Manufacturing》 SCIE EI CAS CSCD 2021年第1期22-33,共12页
Machine chatter is still an unresolved and challenging issue in the milling process,and developing an online chatter identification and process monitoring system towards smart manufacturing is an urgent requirement.In... Machine chatter is still an unresolved and challenging issue in the milling process,and developing an online chatter identification and process monitoring system towards smart manufacturing is an urgent requirement.In this paper,two indicators of chatter detection are investigated.One is the real-time variance of milling force signals in the time domain,and the other one is the wavelet energy ratio of acceleration signals based on wavelet packet decomposition in the frequency domain.Then,a novel classification concept for vibration condition,called slight chatter,is proposed and integrated successfully into the designed multi-classification support vector machine(SVM)model.Finally,a mapping model between image and chatter indicators is established via a distance threshold on the image.The multi-SVM model is trained by the results of three signals as an input.Experiment data and detection accuracy of the SVM model are verified in actual machining.The identification accuracy of 96.66%has proved that the proposed solution is feasible and effective.The presented method can be used to select optimized milling parameters to improve machining process stability and strengthen manufacturing system monitoring. 展开更多
关键词 Chatter milling force ACCELERATION Wavelet packet decomposition MULTI-SENSOR
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