Prediction Method of Cutting Surface Topography of Thin-walled Cylinder Driven by Mechanism and Data Fusion

LYU Kaibo; LI Yaolong; SHI Xin; HU Yang; BAI Shengwen; PANG Xinyu

doi:10.16490/j.cnki.issn.1001-3660.2025.16.013

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Surface Technology ›› 2025, Vol. 54 ›› Issue (16) : 156-164. DOI: 10.16490/j.cnki.issn.1001-3660.2025.16.013

Precision and Ultra-precision Machining

Prediction Method of Cutting Surface Topography of Thin-walled Cylinder Driven by Mechanism and Data Fusion

LYU Kaibo^1,*, LI Yaolong¹, SHI Xin², HU Yang¹, BAI Shengwen², PANG Xinyu¹

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Abstract

Thin-walled cylinder parts which are widely used in automotive and aerospace industry are prone to vibration during machining operations as a result of their high compliance, leading to special textures left on the surface. The aim of this paper is to predict the surface morphology of thin-walled cylinder workpieces in the presence of turning vibrations by digital-model linkage modeling. A novel prediction model of the cutting surface topography and roughness of thin-walled cylinders based on the combination of the mechanism and online data is established by taking into account the effects of the geometrical parameters of cutting tools and workpieces, machining parameters, and cutting vibration parameters comprehensively. At first, based on the principle of machining, the motion trajectory equation and the coordinate transformation matrix of the points on the cutting edge relative to the workpiece surface in the machining process are derived. Through subtracting the coordinates of the tool and the workpiece at their contact point, the kinematics model of the machined surface of the thin-walled cylinder can be established. After that, machining experiments are conducted on an industrial lathe, in which two thin-walled cylinder workpieces with different dimensions are presented for comparison. In machining operations, one side of the machined cylinder is clamped with the chuck and the other is free without the tailstock center support. Two orthogonal eddy current sensors are used to acquire the displacement of the thin-walled cylinders. In addition, a MarSurf PS10 roughness measuring instrument is utilized to attain the surface roughness distribution along the axis of the workpiece after each cutting pass. It shows that the dynamic response as well as the machined surface topography of the thin-walled cylinder can exhibit strong variability along the cutting path. Finally, the time-frequency analysis is used to extract the characteristics of workpiece vibration signals for constructing the characteristic equations in different cutting process states. The mapping relationship between the characteristics of surface topography and the frequency features of vibration signals is identified. The constructed characteristic vibration equation is then substituted into the kinematic mechanism model to simulate and calculate the surface topography, and the surface topography and roughness of the thin-walled cylinder under different machining parameters are obtained using numerical simulation. It can be seen that the predicted surface shows consistency with the measured surface. And the relative error between the simulated surface roughness and the measured surface roughness of workpiece A in the stable cutting zone is 4.27%, and the average relative error in the chattering zone is 6.03%. The relative error between the simulated surface roughness and the measured surface roughness of workpiece B in the stable region is 3.61%, and the relative error in the chattering region is 2.42%. The results of this research can provide a theoretical basis for on-line monitoring and control of the cutting surface quality of thin-walled cylinder parts in intelligent machining scenarios. In addition, the formulated mapping relation between the vibration characteristics and the surface topography provides an overall insight into vibration behaviors of thin-walled cylinder workpieces during machining processes.

Key words

thin-walled cylinder / cutting / vibration / surface topography / digital-model linkage / roughness

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LYU Kaibo, LI Yaolong, SHI Xin, HU Yang, BAI Shengwen, PANG Xinyu. Prediction Method of Cutting Surface Topography of Thin-walled Cylinder Driven by Mechanism and Data Fusion[J]. Surface Technology. 2025, 54(16): 156-164 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.16.013

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