Machine tool systems structural characterization, energy transfer, and evolution analysis of milling Ti6Al4V considering cutting vibration

During high-efficiency milling, the mechanical status of the tool system, consisting of the tool and tool holder, is constantly changing due to the high-speed cyclic cutting load and the self-excited vibration of the cutting force. The dynamic mechanical status has a significant impact on the relative position between the tool and workpiece, which directly affects the machining error. Clarification of the dynamics of the tool system subjected to high-speed cutting loads plays a key role for better understanding the energy transfer and offset distribution of the tool system. This paper presented a dynamic model of the tool system in high-efficiency milling process. The hierarchical structure and response characteristics of the energy consumption of milling tool system’s interface were researched, the transmission path and distribution of the energy consumption were investigated, and a method for identifying the factors affecting the dynamic energy consumption of milling tool system’s interface was proposed. The changing law in relative position of the tool system under the effect of high-speed cutting load was unveiled. Milling machining experiments were conducted to verify the accuracy of the proposed models.