Dynamic Modeling and Analysis for Thin-Wall Plate Machining

Complex thin-wall component machining has been a challenging task in advanced manufacturing because distributed deformation and vibration of workpiece render poor precision in final products, which requires displacement field measurements for vibration compensation techniques to enhance product quality. It is desired to capture the distributed and dynamic characteristics of workpiece during the machining of thin-wall plates. In the context of an engineering application where an annular compressor disk is lathe-turned on a duplex machine, this paper has developed an analytical method to capture the effects of stepped thickness on the thin-wall plate dynamics, where the stepped shape emulates the geometry of a workpiece under machining. Modal natural frequencies characterizing varying inertia and stiffness are obtained via a formulated boundary value problem, upon which the effects of cutting tool positions on the frequencies and mode shapes are analyzed. It also provides numerical verification with finite element analysis and validation with experiment.